Yamaha TMAX 2020 Service Manual

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2020

SERVICE MANUAL

TMAX

TMAX TECH MAX

XP560EL

XP560D

B3T-28197-20

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Page 1 2020 SERVICE MANUAL TMAX TMAX TECH MAX XP560EL XP560D B3T-28197-20...
Page 3 EAS20003 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Page 4 EAS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex- planations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
Page 5 EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
Page 7: Table Of Contents
TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM SELF DIAGNOSTIC...
Page 9: General Information
GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 MULTI-FUNCTION DISPLAY..............1-2 CANCELING THE SIDESTAND ALARM BEEPER.........1-11 SPECIAL TOOLS ..................1-12...
Page 10: Identification
IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped onto the right side of the frame. EAS30003 MODEL LABEL The model label “1” is affixed to the storage box. This information will be needed to order spare parts.
Page 11: Features
FEATURES EAS20008 Fuel meter FEATURES EAS30618 MULTI-FUNCTION DISPLAY 1. Fuel meter The fuel meter indicates the amount of fuel in the fuel tank. The display segments of the fuel meter 1. Information display disappear from “F” (full) towards “E” (empty) as 2.
Page 12 FEATURES Eco indicator This indicator flashes every 20000 km (12500 mi) when the V-belt needs to be replaced. After changing the V-belt, reset the V-belt re- placement indicator. If the V-belt is changed before the V-belt re- placement indicator flashes, the indicator must be reset in order for the next periodic V-belt change to be indicated at the correct time.
Page 13 FEATURES Function selection Adjusting the seat heater This vehicle can be equipped with a seat heater, which can only be used when the vehicle is run- ning. There are 4 seat heater settings. Setting Display Middle Push the “MENU” switch to switch among the High windshield adjusting function, grip warmer ad- justing function, seat heater adjusting function,...
Page 14 FEATURES Push the “ ” or “ ” side of the select switch to F-TRIP Display–1 Display–2 Dis- rotate among the 3 display pages. play–3 F-TRIP If you do not reset the fuel reserve tripmeter The items for each display page can be custom- manually, it will reset automatically after refuel- ized.
Page 15 FEATURES Menu items After resetting the average fuel consumption dis- Display Description play, “– –.–” will be shown until the vehicle has This function allows you to traveled 1 km (0.6 mi). set the low, middle, and high Grip Warmer settings to 10 temperature ECA25730 levels.
Page 16 FEATURES 2. Push the “MENU” switch. The grip warmer 2. Push the “MENU” switch. The seat heater setting display will be shown. setting display will be shown. 3. Push the “MENU” switch. The temperature 3. Push the “MENU” switch. The temperature level for the high setting will be highlighted.
Page 17 FEATURES 2. Push the “MENU” switch. The traction control 2. Push the “MENU” switch, and then use the system setting display will be shown. select switch to select the item to reset. 3. To set the traction control system to “OFF”, 3.
Page 18 FEATURES 2. Push the “MENU” switch. The unit setting dis- 3. Use the select switch to highlight the item to play will be shown. change, and then push the “MENU” switch. 3. Use the select switch to select “L/100km” or “km/L”.
Page 19 FEATURES Meter panel brightness 2. Push the “MENU” switch. 1. Use the select switch to highlight “Bright- 3. When the hour digits are highlighted, use the ness”. select switch to set the hours. 2. Push the “MENU” switch. 4. Push the “MENU” switch, and the minute dig- 3.
Page 20: Canceling The Sidestand Alarm Beeper
FEATURES 2. Push the “MENU” switch. Setting procedure 3. Use the select switch to highlight “YES”, and 1. Set the engine stop switch “ ” “1” to “ ”. then push the “MENU” switch. All items are reset to factory preset or default settings. 2.
Page 21: Special Tools
• For U.S.A. and Canada, use part numbers starting with “YM-”, “YU-”, or “ACC-”. • For others, use part numbers starting with “90890-”. Reference Tool name/Tool No. Illustration pages Yamaha diagnostic tool USB 3-4, 3-12, 4-70, 90890-03267 4-71, 7-13, 9-3, 9-36, 9-37 Yamaha diagnostic tool (A/I)
Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Carburetor angle driver 2 3-10 90890-03173 Tension meter (TEXA) 3-21 90890-03258 Steering nut wrench 3-24, 4-92 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-27, 6-8 90890-01426 Oil filter wrench YU-38411 Oil pressure gauge set 3-29 90890-03120...
Page 23 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper rod holder (ø27) 4-84, 4-87 90890-01423 Damping rod holder YM-01423 Fork seal driver 4-86, 4-86, 4-86 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Rod puller 4-87 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Rod puller attachment (M10)
Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve spring compressor attachment 5-24, 5-28 90890-04114 Valve spring compressor adapter 19.5 YM-04114 Valve guide remover (ø4) 5-25 90890-04111 Valve guide remover (4.0 mm) YM-04111 Valve guide installer (ø4) 5-25 90890-04112 Valve guide installer (4.0 mm) YM-04112 Valve guide reamer (ø4) 5-25...
Page 25 Sheave spring compressor 5-43, 5-46 90890-04134 Sheave spring compressor YM-04134 Sheave fixed block 5-43, 5-46 90890-04135 Sheave fixed bracket YM-04135 Yamaha bond No. 1215 5-47, 5-54, 5-71 90890-85505 (Three bond No.1215®) Sheave holder 5-52, 5-52, 90890-01701 5-53, 5-54 Primary clutch holder YS-01880-A...
Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Flywheel puller 5-52 90890-01362 Heavy duty puller YU-33270-B Rotor holding tool 5-58, 5-61 90890-01235 Universal magneto and rotor holder YU-01235 Clutch spring compressor 5-58, 5-61 90890-01482 Universal clutch holder 5-58, 5-60 90890-04086 Universal clutch holder YM-91042 Plane bearing installer...
Page 27 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester adapter 6-5, 6-5 90890-01352 Pressure tester adapter YU-33984 YU-33984 Mechanical seal installer (ø33) 6-14 90890-04132 Water pump seal installer (ø33) YM-33221-A Middle driven shaft bearing driver 6-14 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Fuel injector pressure adapter 7-12...
Page 28 SPECIAL TOOLS Yamaha diagnostic tool (A/I) 90890-03264 This special tool includes the YDT sub harness (6P) (90890-03266). YDT sub harness (6P) 90890-03266 If you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890-03266) is separately required. 1-19...
Page 29: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-9 TIGHTENING TORQUES ................2-11 ENGINE TIGHTENING TORQUES............2-11 CHASSIS TIGHTENING TORQUES............2-11 CABLE ROUTING ..................2-13...
Page 30: General Specifications
GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model B3T2 (XP560E) B7M2 (XP560D_RUS) B7M6 (XP560D_ZAF) Dimensions Overall length 2200 mm (86.6 in) Overall width 765 mm (30.1 in) Overall height 1420/1475 mm (55.9/58.1 in) (XP560E) 1420/1555 mm (55.9/61.2 in) (XP560D) Wheelbase 1575 mm (62.0 in) Ground clearance 125 mm (4.92 in) Minimum turning radius...
Page 31: Engine Specifications
ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 562 cm³ Cylinder arrangement Inline Number of cylinders 2-cylinder Bore  stroke 70.0  73.0 mm (2.76  2.87 in) Compression ratio 10.9 : 1 Compression pressure 1653–2128 kPa/360 r/min (16.5–21.3 kgf/cm²/ 360 r/min, 235.1–302.7 psi/360 r/min)
Page 32 ENGINE SPECIFICATIONS Cylinder head Warpage limit 0.10 mm (0.0039 in) Camshaft Camshaft cap inside diameter 23.000–23.021 mm (0.9055–0.9063 in) Camshaft journal diameter 22.959–22.972 mm (0.9039–0.9044 in) Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) Limit 0.080 mm (0.0032 in) Camshaft lobe dimensions Lobe height (Intake) 32.490–32.590 mm (1.2791–1.2831 in) Limit...
Page 33 ENGINE SPECIFICATIONS Piston Diameter 69.975–69.990 mm (2.7549–2.7555 in) Measuring point (from piston skirt bottom) 8.0 mm (0.31 in) Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in) Piston pin bore inside diameter 17.002–17.013 mm (0.6694–0.6698 in) Limit 17.043 mm (0.6710 in) Piston pin outside diameter 16.995–17.000 mm (0.6691–0.6693 in) Limit 16.975 mm (0.6683 in)
Page 34 ENGINE SPECIFICATIONS Clutch Clutch type Wet, centrifugal, multiple-disc Friction plate thickness 2.92–3.08 mm (0.115–0.121 in) Plate quantity 6 pcs Wear limit 2.82 mm (0.111 in) Clutch plate 1 thickness 1.30-1.50 mm (0.051-0.059 in) Plate quantity 5 pcs Warpage limit 0.10 mm (0.004 in) Clutch plate 2 thickness 1.80-2.00 mm (0.071-0.079 in) Plate quantity...
Page 35 ENGINE SPECIFICATIONS Accelerator position sensor Resistance 1.08–2.52 k Idling condition Engine idling speed 1100–1300 r/min O2 feedback control Active 85–105 C (185–221 F) Coolant temperature Intake vacuum 34.0 kPa (255 mmHg, 10.0 inHg) Difference in vacuum pressure between the cylinders 0 kPa–1.3 kPa (0 mmHg–10 mmHg, 0 inHg–...
Page 36: Chassis Specifications
CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond 26.0  Caster angle Trail 98 mm (3.9 in) Front wheel Wheel type Cast wheel Rim size 15M/C x MT3.5 Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) Wheel axle bending limit 0.25 mm (0.01 in)
Page 37 287.8 mm (11.33 in) Limit 282.0 mm (11.10 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil 01 Quantity (left) 444.0 cm³ (15.01 US oz) Quantity (right) 434.0 cm³ (14.67 US oz) Level (left) 114 mm (4.5 in) Level (right) 118 mm (4.6 in)
Page 38: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system 3.0–7.0 /1200 r/min Ignition timing (B.T.D.C.) Engine control unit Model TBDF4Q (XP560D) TBDF4U (XP560E) Ignition coil 1.87–2.53  Primary coil resistance Secondary coil resistance 12.00–18.00 k Spark plug cap Resistance 7.50–12.50 k...
Page 39 ELECTRICAL SPECIFICATIONS ABS warning light Cruise control “SET” indicator light LED (XP560D) Cruise control “ON” indicator light LED (XP560D) Smart key system indicator light Traction control system indicator light Starter motor Brush overall length limit 6.5 mm (0.26 in) Brush spring force 6.02–6.51 N (614–664 gf, 21.69–23.45 oz) Mica undercut (depth) 0.70 mm (0.03 in)
Page 40: Tightening Torques
TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 20 N·m (2.0 kgf·m, 15 lb·ft) Muffler protector bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) Front muffler protector bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Cylinder head cover bolt...
Page 41 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Drive pulley assembly bolt 48 N·m (4.8 kgf·m, 35 lb·ft) Front wheel axle pinch bolt 1. Insert the front wheel axle from the right side, temporarily install the front wheel axle bolt “1” from the left side, and then tighten the front wheel axle to 91 N·m (9.1 kgf·m, 67 lb·ft).
Page 42: Cable Routing
CABLE ROUTING EAS20021 CABLE ROUTING Headlight bracket (front view) 2-13...
Page 43 CABLE ROUTING 1. Handlebar switch coupler 1 (left) (black) 2. Front brake light switch coupler (black) (for XP560D) 3. Rear brake light switch coupler (white) (for XP560D) 4. Handlebar switch coupler 2 (right) (white) 5. Handlebar switch lead (left/right)/Grip warmer lead (left/right) (for XP560D)/Front brake light switch lead (for XP560D)/Rear brake light switch lead (for XP560D) 6.
Page 44 CABLE ROUTING Front cowling assembly (rear view) 2-15...
Page 45 CABLE ROUTING 1. Headlight control unit 2. Clamp 3. Front turn signal light coupler 4. Headlight sub-wire harness 5. Headlight assembly lead A. Do not pass the wire harness through this location. B. After assembling the headlight, route wires to the wire harness. C.
Page 46 CABLE ROUTING Frame (right side view) (front) 2-17...
Page 47 CABLE ROUTING P. Route the rear brake lock cable between 1. Storage compartment lid lock solenoid coupler (for XP560D) the frame and the brake hose. 2. Remote control unit lead (for XP560D) Q. Route the rectifier/regulator lead between the wire harness and the electrical compo- 3.
Page 48 CABLE ROUTING Frame (right side view) (rear) 2-19...
Page 49 CABLE ROUTING 1. Storage box light switch lead 2. Rear wheel sensor lead 3. Battery charger terminal (OPTION) 4. O sensor lead 5. Storage box light lead 6. Storage box 7. Storage box rib 8. Starter motor lead 9. Rear brake lock cable 10.
Page 50 CABLE ROUTING Frame (left side view) (front) 2-21...
Page 51 CABLE ROUTING Install the wire harness coupler into the 1. Buzzer lead hole in the bracket. 2. Intake air temperature sensor lead J. Pass the three lead wires more toward the 3. YDT coupler inside of the vehicle than the wire harness. 4.
Page 52 CABLE ROUTING Rear frame (left side view) (center) 2-23...
Page 53 CABLE ROUTING Q. Fasten the sidestand switch lead to the 1. Centerstand lock solenoid lead footboard with the plastic locking tie. Point 2. Sidestand switch the end of the plastic locking tie rearward 3. Starter motor lead and place it inside of the footboard. 4.
Page 54 CABLE ROUTING Frame (left side view) (rear) 2-25...
Page 55 CABLE ROUTING 1. Stator coil coupler 2. Turn signal/hazard relay 3. Radiator fan motor relay 4. Seat heater relay (power) (for XP560D) 5. Seat heater relay (control) (for XP560D) 6. Windshield drive unit relay (down) (for XP560D) 7. Windshield drive unit relay (up) (for XP560D) 8.
Page 56 CABLE ROUTING Frame (top view) (front) 2-27...
Page 57 CABLE ROUTING 1. Fuse box 4 (for XP560D) 2. Fuse box 5 (for XP560D) 3. Fuse box 2 4. Starter relay lead 5. Fuse box 1 6. Fuse box 3 7. ABS ECU coupler 8. Lean angle sensor 9. Intake air pressure sensor lead 10.
Page 58 CABLE ROUTING Frame (top view) (rear) 2-29...
Page 59 CABLE ROUTING 1. Seat/fuel lid lock solenoid coupler 2. Seat lock cable 3. Tail/brake light lead (right) 4. Tail cover 5. Tail/brake light 6. Tail/brake light lead (left) 7. Storage box light 8. Windshield drive unit relay (up) (for XP560D) 9.
Page 60 CABLE ROUTING Handlebar (top and left side view) (for XP560E) 2-31...
Page 61 CABLE ROUTING 1. Rear brake lock cable 2. Handlebar cover 3. Throttle cable (decelerator cable) 4. Throttle cable (accelerator cable) 5. Rear brake lock lever 6. Front brake hose (front brake master cylin- der to hydraulic unit) 7. Front brake master cylinder 8.
Page 62 CABLE ROUTING Handlebar (front view) (for XP560E) 2-33...
Page 63 CABLE ROUTING S. Fasten the handlebar switch lead (left) and 1. Front brake master cylinder handlebar switch lead (right) with the 2. Front brake hose (front brake master cylin- clamp. The positions of the wires are arbi- der to hydraulic unit) trary.
Page 64 CABLE ROUTING Handlebar (top and left side view) (for XP560D) 2-35...
Page 65 CABLE ROUTING 1. Rear brake lock cable 2. Handlebar cover 3. Throttle cable (decelerator cable) 4. Throttle cable (accelerator cable) 5. Rear brake lock lever 6. Grip warmer (left) 7. Front brake hose (front brake master cylin- der to hydraulic unit) 8.
Page 66 CABLE ROUTING Handlebar (front view) (for XP560D) 2-37...
Page 67 CABLE ROUTING N. The metal part of the front brake hose 1. Front brake master cylinder should come into contact with the guide 2. Front brake hose (front brake master cylin- section of the front brake master cylinder. der to hydraulic unit) O.
Page 68 CABLE ROUTING Front brake (front, left side and right side view) 2-39...
Page 69 CABLE ROUTING N. Fasten the front brake hose and white tape 1. Headlight bracket section of the front wheel sensor lead with 2. Front brake hose (hydraulic unit to front the clamp. Fasten the front brake hose brake caliper) (hydraulic unit to front brake caliper) and 3.
Page 70 CABLE ROUTING Frame (right side view) (front) 2-41...
Page 71 CABLE ROUTING 1. Rear frame 2. Rear brake hose (hydraulic unit to rear brake caliper) 3. Rear brake lock cable 4. Electrical components tray 5. Guide 6. Footrest bracket 7. Frame 8. Plastic locking tie 9. Clamp 10. Rear wheel sensor lead 11.
Page 72 CABLE ROUTING Rear brake (right side view) (rear) 2-43...
Page 73 CABLE ROUTING 1. Rear brake lock caliper 2. Rear brake lock cable 3. Holder 4. Rear brake hose (hydraulic unit to rear brake caliper) 5. Swingarm (right) 6. Clamp 7. Rear brake caliper 8. Rear wheel sensor lead 9. Rear brake disc 10.
Page 74 CABLE ROUTING Fuel tank (right side view) 2-45...
Page 75 CABLE ROUTING 1. Fuel tank breather hose (fuel tank to roll- over valve) 2. Fuel tank 3. Clamp 4. Rear brake hose (hydraulic unit to rear brake caliper) 5. Fuel tank breather hose (rollover valve to canister) 6. Rollover valve 7.
Page 76 CABLE ROUTING Fuel tank (left side view) 2-47...
Page 77 CABLE ROUTING 1. Fuel tank overflow hose 2. Hose joint 3. Fuel tank cap 4. Filler cover 5. Fuel tank 6. Frame 7. Sidestand bracket 8. Fuel pump 9. Fuel pump lead 10. Fuel hose 11. Fuel pump bracket A. Install the fuel tank overflow hose with the mark facing the outside.
Page 78 CABLE ROUTING Fuel tank (top view) 2-49...
Page 79 CABLE ROUTING 1. Canister bracket 2. Canister holder 3. Canister 4. Fuel tank breather hose (rollover valve to canister) 5. Rollover valve 6. Fuel tank breather hose (fuel tank to roll- over valve) 7. Fuel tank 8. Throttle body assembly 9.
Page 80 CABLE ROUTING Air filter case and throttle body (left side view) 2-51...
Page 81 CABLE ROUTING 1. Air filter element 2. Intake air pressure sensor 3. Fuel tank bracket 4. Throttle body assembly 5. Fuel tank 6. Air filter case 7. Fuel hose 8. Air filter case duct (right) 9. Canister purge hose (hose joint to canis- ter) 10.
Page 82 CABLE ROUTING Radiator (right side view) 2-53...
Page 83 CABLE ROUTING T. Align the yellow paint mark on the radiator 1. Oil cooler inlet hose inlet hose with the punch mark on the radi- 2. Cooling system air bleed hose ator to assemble them. 3. Throttle position sensor lead U.
Page 84 CABLE ROUTING Radiator (left side view) 2-55...
Page 85 CABLE ROUTING Y. Make sure the hose clamp dose not ride 1. Coolant reservoir on top of the bulge in the hose mounting 2. Coolant reservoir breather hose area. 3. Footrest bracket Z. 3 mm (0.12 in) or more 4. Coolant hose AA.0–1 mm (0–0.04 in) 5.
Page 86 CABLE ROUTING Radiator (top view) 2-57...
Page 87 CABLE ROUTING 1. Radiator cap 2. Radiator filler hose 3. Coolant reservoir hose 4. Radiator bracket 5. Frame 6. Oil cooler inlet hose 7. Coolant hose 8. Oil cooler outlet hose 9. Radiator outlet hose 10. Coolant reservoir 11. Footrest bracket 12.
Page 88 CABLE ROUTING Hydraulic unit assembly (top and front view) 2-59...
Page 89 CABLE ROUTING 1. Rear brake hose (hydraulic unit to rear brake caliper) 2. Rear brake hose (rear brake master cylin- der to hydraulic unit) 3. Front brake hose (front brake master cylin- der to hydraulic unit) 4. Front brake hose (hydraulic unit to front brake caliper) 5.
Page 90 CABLE ROUTING 2-61...
Page 91: Periodic Checks And Adjustments
INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC TOOL ......................3-4 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS ............. 3-5 ADJUSTING THE VALVE CLEARANCE ..........3-5 CHECKING THE ENGINE IDLING SPEED ..........3-8...
Page 92 CHECKING THE CHASSIS FASTENERS ..........3-25 LUBRICATING THE LEVERS ..............3-25 CHECKING THE SIDESTAND..............3-25 LUBRICATING THE SIDESTAND............3-25 CHECKING THE CENTERSTAND ............3-25 LUBRICATING THE CENTERSTAND ............3-25 CHECKING THE SIDESTAND SWITCH..........3-25 CHECKING THE FRONT FORK ............. 3-25 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....3-25 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY (for XP560D)...................
Page 93: Periodic Maintenance
All service technicians should be familiar with this entire chapter. • Items marked with an asterisk should be performed by your Yamaha dealer because these items require special tools, data, and technical skills.
Page 94 PERIODIC MAINTENANCE ODOMETER READINGS CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check operation, fluid level, and for fluid leakage.  ...
Page 95 PERIODIC MAINTENANCE ODOMETER READINGS CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) Front and rear       28 * •...
Page 96: Checking The Vehicle Using The Yamaha Diagnostic Tool
• Yamaha diagnostic tool (A/I) (90890-03264) in- 2. Check: cludes YDT sub harness (6P) (90890-03266). • Fuel hose “1” • If you already have Yamaha diagnostic tool (A/ • Fuel tank overflow hose “2” I) (90890-03262), YDT sub harness (6P) • Fuel tank breather hose “3”...
Page 97: Checking The Spark Plugs
PERIODIC MAINTENANCE 3. Install: 7. Measure: • Fuel tank • Spark plug gap “a” Refer to “FUEL TANK” on page 7-1. (with a wire thickness gauge) Out of specification  Regap. • Footboard • Rear side cowling assembly • Side cover Spark plug gap 0.7–0.8 mm (0.028–0.031 in) •...
Page 98 PERIODIC MAINTENANCE • Center cover • Fuel tank cover assembly • TDC on the compression stroke can be found • Side cover when the cylinder #1 camshaft lobes are • Rear side cowling assembly turned away from each other. • Footboard •...
Page 99 PERIODIC MAINTENANCE • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. • Make a note of the position of each valve lifter and valve pad so that they can be installed in the correct place.
Page 100: Checking The Engine Idling Speed
PERIODIC MAINTENANCE i. If the valve clearance is still out of specifica- Last digit Rounded value tion, repeat all of the valve clearance ad- 0, 1, 2 justment steps until the specified clearance 3, 4, 5, 6 is obtained. 7, 8, 9 8.
Page 101: Synchronizing The Throttle Bodies
PERIODIC MAINTENANCE EAS30797 SYNCHRONIZING THE THROTTLE BODIES Vacuum gauge 90890-03094 Before synchronizing the throttle bodies, check Vacuummate the following items: YU-44456 • Valve clearance • Spark plug • Air filter element • Throttle body joint • Fuel hose • Exhaust system •...
Page 102: Checking The Throttle Body Joints
PERIODIC MAINTENANCE Adjusting the throttle body synchronization 3. Install: 1. Adjust: • Intake air pressure sensor hose • Throttle body synchronization • Cap 4. Install: a. Start the engine, warm it up for several min- • Fuel tank utes, and then let it run at the specified en- Refer to “FUEL TANK”...
Page 103: Checking The Exhaust System
PERIODIC MAINTENANCE • Center cover 4. Install: Refer to“GENERAL CHASSIS (2)” on • Footboard (right) page 4-11. • Rear side cowling assembly (right) • Bottom center cowling • Side cover (right) • Side panel • Fuel tank cover assembly • Bottom side cowling •...
Page 104: Checking The Canister
• Yamaha diagnostic tool (A/I) (90890-03264) in- • Center cover cludes YDT sub harness (6P) (90890-03266). • Fuel tank cover assembly • If you already have Yamaha diagnostic tool (A/ • Side cover I) (90890-03262), YDT sub harness (6P) • Rear side cowling assembly (90890-03266) is separately required.
Page 105: Cleaning The V-Belt Case Air Filter Element
PERIODIC MAINTENANCE 3. Remove: • V-belt case air filter case cover • Replace the air filter element every 20000 km • V-belt case air filter case (12000 mi) of operation. • V-belt case air filter element (right) • The air filter needs more frequent service if you Refer to “V-BELT AUTOMATIC TRANSMIS- are riding in unusually wet or dusty areas.
Page 106: Checking The Brake Operation
PERIODIC MAINTENANCE EWA13540 WARNING V-belt case air filter element joint • Use only the designated brake fluid. Other clamp (left side) brake fluids may cause the rubber seals to 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) deteriorate, causing leakage and poor 8.
Page 107: Checking The Front Brake Pads
PERIODIC MAINTENANCE EAS30631 ADJUSTING THE REAR DISC BRAKE 1. Adjust: • Rear brake lever position (distance “a” from the left side grip to the brake lever) G088890 EWA17050 WARNING • After adjusting the brake lever position, make sure the pin on the brake lever holder is firmly inserted in the hole in the adjusting G107370 dial.
Page 108: Checking The Rear Brake Pads
PERIODIC MAINTENANCE EAS30634 EAS30893 CHECKING THE REAR BRAKE PADS BLEEDING THE HYDRAULIC BRAKE The following procedure applies to all of the SYSTEM brake pads. EWA14000 WARNING 1. Operate the brake. Always bleed the brake system when the 2. Check: brake related parts are removed. •...
Page 109: Adjusting The Rear Brake Lock Cable
PERIODIC MAINTENANCE Front brake caliper bleed screw 6 N·m (0.6 kgf·m, 4.4 lb·ft) Rear brake caliper bleed screw 6 N·m (0.6 kgf·m, 4.4 lb·ft) m. Fill the brake master cylinder reservoir to the proper level with the specified brake flu- Refer to “CHECKING THE BRAKE FLUID LEVEL”...
Page 110: Checking The Rear Brake Lock
PERIODIC MAINTENANCE 3. Adjust: Refer to “ADJUSTING THE REAR BRAKE • Clearance between the brake pad and brake LOCK CABLE” on page 3-17 and “CHECK- disc. ING THE REAR BRAKE LOCK PADS” on page 3-18. a. Remove the cap of the rear brake lock ad- 2.
Page 111: Checking The Wheels
WARNING en if a tire combination other than one • The tire pressure should only be checked approved by Yamaha is used on this vehicle. and regulated when the tire temperature equals the ambient air temperature. • The tire pressure and the suspension must...
Page 112: Checking The Wheel Bearings
PERIODIC MAINTENANCE G088891 3. Check: EAS30641 CHECKING THE WHEEL BEARINGS • Drive belt The following procedure applies to all of the Exposed cogs or external cracks “A”  wheel bearings. Replace. 1. Check: Missing teeth “B”  Replace. • Wheel bearings Hook wear “C”...
Page 113: Drive Belt Tension
PERIODIC MAINTENANCE EAS32399 DRIVE BELT TENSION Checking the drive belt tension EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. ECA25750 NOTICE A drive belt that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swing- arm or cause an accident.
Page 114: Lubricating The Drive Pulley And Drive Axle
Lubricate portion “a” of the drive axle with grease. Recommended lubricant YAMAHA GREASE “J” (Shell Alvania EP Grease R0®) 3. Check the difference in the distance “a” be- tween the left and right sides should be 0.8 mm (0.03 in) or less.
Page 115: Checking And Adjusting The Steering Head
(Shell Alvania EP Grease R0®) into the hole “a” in the tip of the drive axle. Continue inject- ing until the YAMAHA GREASE “J” (Shell Al- vania EP Grease R0®) comes out of the side holes “b” on the drive axle.
Page 116: Lubricating The Steering Head
PERIODIC MAINTENANCE 2. Check: EWA13140 WARNING • Steering head Do not overtighten the lower ring nut. Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness  Adjust the steering Lower ring nut (final tightening head.
Page 117: Checking The Chassis Fasteners
PERIODIC MAINTENANCE EAS31186 EAS30653 CHECKING THE CHASSIS FASTENERS CHECKING THE FRONT FORK Make sure that all nuts, bolts, and screws are 1. Stand the vehicle on a level surface. properly tightened. EWA13120 WARNING Refer to “CHASSIS TIGHTENING TORQUES” Securely support the vehicle so that there is on page 2-11.
Page 118: Checking The Connecting Arm And Relay Arm
PERIODIC MAINTENANCE Spring preload Direction “a” ECA13590 NOTICE Rebound damping is increased Never go beyond the maximum or minimum (suspension is harder). adjustment positions. Direction “b” Rebound damping is decreased 1. Adjust: (suspension is softer). • Spring preload a. Adjust the spring preload with the special Rebound damping wrench “1”...
Page 119: Checking The Engine Oil Level
PERIODIC MAINTENANCE EAS30656 CHECKING THE ENGINE OIL LEVEL Before checking the engine oil level, wait a few 1. Stand the vehicle on a level surface. minutes until the oil has settled. • Place the vehicle on the centerstand. EAS30657 • Make sure the vehicle is upright. CHANGING THE ENGINE OIL 1.
Page 120 PERIODIC MAINTENANCE 10.Check: • Engine (for engine oil leaks) 11.Check: • Engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL” on page 3-27. 12.Check: • Engine oil pressure a. Remove the bottom side cowling and bot- b. Lubricate the O-ring of the new oil filter car- tom center cowling.
Page 121: Measuring The Engine Oil Pressure
PERIODIC MAINTENANCE EAS30810 ECA13410 MEASURING THE ENGINE OIL PRESSURE NOTICE 1. Remove: When the engine is cold, the engine oil will • Engine oil pressure check point plug “1” have a higher viscosity, causing the engine (Bottom of the crankcase) oil pressure to increase.
Page 122: Checking The Cooling System
PERIODIC MAINTENANCE Below the minimum level mark  Remove • Fuel tank cover assembly the left footboard mat, coolant reservoir cap • Side cover access panel “1”, and coolant reservoir cap, • Rear side cowling assembly and then add the recommended coolant to •...
Page 123: Changing The Coolant
PERIODIC MAINTENANCE • Radiator cover • Side panel When removing the radiator cap, hold the radia- • Bottom side cowling tor filler pipe “2”. Refer to “GENERAL CHASSIS (1)” on page 4-1. EAS30813 CHANGING THE COOLANT 1. Remove: • Bottom side cowling •...
Page 124: Replacing The V-Belt
PERIODIC MAINTENANCE Recommended antifreeze High-quality ethylene glycol anti- freeze containing corrosion inhibi- tors for aluminum engines Mixing ratio 1:1 (antifreeze : water) Radiator (including all routes) 1.54 L (1.63 US qt) Coolant reservoir (up to the maximum level mark) 12.Install: 0.25 L (0.26 US qt) •...
Page 125: Checking The Brake Light Switches
PERIODIC MAINTENANCE • Outer V-belt case 1. Check: Refer to “V-BELT AUTOMATIC TRANSMIS- • Outer cable Damage  Replace. SION” on page 5-39. 2. Check: 2. Check: • V-belt • Cable operation Cracks/damage/wear  Replace. Rough movement  Lubricate. Grease/oil  Clean the primary and second- ary pulleys.
Page 126: Checking And Charging The Battery
PERIODIC MAINTENANCE EAS30664 ADJUSTING THE HEADLIGHT BEAMS 1. Adjust: • Headlight beam (vertically) a. Turn the adjusting screw “1”. Other than the socket wrench, the adjusting screws can be turned with a screwdriver (Phillips No. 2) “2” as shown in the illustration. G088895 4.
Page 127: Chassis
CHASSIS GENERAL CHASSIS (1) ................. 4-1 ADJUSTING THE WINDSHIELD HEIGHT (for XP560E) ......4-7 REMOVING THE FRONT COVER............4-7 REMOVING THE SIDE PANEL..............4-8 INSTALLING THE SIDE PANEL ............... 4-9 REMOVING THE INNER PANEL.............. 4-9 REMOVING THE BATTERY COVER .............4-10 GENERAL CHASSIS (2) ................4-11 REMOVING THE SIDE COVER..............4-15 REMOVING THE REAR SIDE COWLING ..........
Page 128 FRONT BRAKE ..................... 4-38 INTRODUCTION ..................4-43 CHECKING THE FRONT BRAKE DISCS..........4-43 REPLACING THE FRONT BRAKE PADS ..........4-43 REMOVING THE FRONT BRAKE CALIPERS ........4-45 DISASSEMBLING THE FRONT BRAKE CALIPERS......4-45 CHECKING THE FRONT BRAKE CALIPERS ........4-45 ASSEMBLING THE FRONT BRAKE CALIPERS........4-46 INSTALLING THE FRONT BRAKE CALIPERS ........
Page 129 FRONT FORK....................4-81 REMOVING THE FRONT FORK LEGS..........4-83 DISASSEMBLING THE FRONT FORK LEGS ........4-83 CHECKING THE FRONT FORK LEGS ..........4-84 ASSEMBLING THE FRONT FORK LEGS ..........4-85 INSTALLING THE FRONT FORK LEGS ..........4-89 STEERING HEAD..................4-90 REMOVING THE LOWER BRACKET.............4-92 CHECKING THE STEERING HEAD ............4-92 INSTALLING THE STEERING HEAD .............4-92 BELT DRIVE....................
Page 130: General Chassis (1)
GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the windshield and meter assembly (for XP560E) 1.6 N ・ m (0.16 kgf ・ m, 1.2 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.5 N ・...
Page 131 GENERAL CHASSIS (1) Removing the windshield and meter assembly (for XP560D) 1.6 N ・ m (0.16 kgf ・ m, 1.2 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.5 N ・...
Page 132 GENERAL CHASSIS (1) Removing the front turn signal light and front cowling assembly 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 2.8 N ・...
Page 133 GENERAL CHASSIS (1) Removing the bottom cowling 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・...
Page 134 GENERAL CHASSIS (1) Removing the battery and leg shield assembly 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) 4.3 N ・ m (0.43 kgf ・ m, 3.2 lb ・ ft) 4.0 N ・...
Page 135 GENERAL CHASSIS (1) Removing the battery and leg shield assembly 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) 4.3 N ・ m (0.43 kgf ・ m, 3.2 lb ・ ft) 4.0 N ・...
Page 136: Adjusting The Windshield Height (For Xp560E)
GENERAL CHASSIS (1) EAS31397 e. Tighten the screws to the specified torque. ADJUSTING THE WINDSHIELD HEIGHT (for XP560E) Windshield screw 1. Adjust: 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Windshield height f. Install the caps “1” a. Remove the windshield covers “1” by re- moving the quick fasteners “2”.
Page 137: Removing The Side Panel
GENERAL CHASSIS (1) b. Remove the front cover bolt “3”. a. Remove the side panel screws “2”. b. Remove the quick fasteners “3” and the c. Remove the front cover “1” by sliding it for- side panel bolt “4”. ward. Remove projections “a”...
Page 138: Installing The Side Panel
GENERAL CHASSIS (1) EAS30822 c. Install the side panel screws “4”. INSTALLING THE SIDE PANEL The following procedure applies to both of the Side panel screw side panels. 1.5 N·m (0.15 kgf·m, 1.1 lb·ft) 1. Install: • Side panel “1” 2.
Page 139: Removing The Battery Cover
GENERAL CHASSIS (1) b. Remove the inner panel “1” by moving it in the arrow direction. EAS31677 REMOVING THE BATTERY COVER 1. Remove: • Battery cover “1” a. Remove the battery cover screw “2”. b. Remove the part “a” of the battery cover. c.
Page 140: General Chassis (2)
GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the footboard 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 4.0 N ・...
Page 141 GENERAL CHASSIS (2) Removing the rear cowling and mudguard assembly 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・...
Page 142 GENERAL CHASSIS (2) Removing the rear cowling assembly and seat assembly 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.5 N ・...
Page 143 GENERAL CHASSIS (2) Removing the storage box 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 0.7 N ・ m (0.07 kgf ・ m, 0.52 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 24 lb ・ ft) 16 N ・...
Page 144: Removing The Side Cover
GENERAL CHASSIS (2) EAS31519 2. Remove: REMOVING THE SIDE COVER • Rear side cowling assembly “1” The following procedure applies to both of the side covers. 1. Remove: • Side cover “1” a. Remove the rear side cowling assembly screw, bolt, and quick fastener. EAS31523 REMOVING THE FOOTBOARD a.
Page 145: Removing The Rear Cover
GENERAL CHASSIS (2) b. Remove the footboard “1” by sliding it to the a. Remove the quick fasteners “2” and screws upper side. “3”. EAS31193 REMOVING THE REAR COVER 1. Remove: • Rubber cover “1” 2. Remove: • Grab bar •...
Page 146: General Chassis (3)
GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the battery box and ECU (Engine Control Unit) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 24 lb ・ ft) 43 N ・...
Page 147 GENERAL CHASSIS (3) Removing the electrical components tray (for XP560E) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 18 N ・ m (1.8 kgf ・ m, 13 lb ・ ft) 7 N ・...
Page 148 GENERAL CHASSIS (3) Removing the electrical components tray (for XP560D) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 18 N ・ m (1.8 kgf ・ m, 13 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 7 N ・...
Page 149 GENERAL CHASSIS (3) Removing the headlight bracket 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 35 N ・ m (3.5 kgf ・ m, 26 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 18 N ・...
Page 150: Installing The Windshield Drive Unit (For Xp560D)
GENERAL CHASSIS (3) EAS31850 c. After installing the windshield “1”, operate INSTALLING THE WINDSHIELD DRIVE UNIT the windshield drive unit to check that the (for XP560D) arm of the windshield drive unit can move 1. Check: fully up and down within the prescribed •...
Page 151: Front Wheel
FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 35 N ・ m (3.5 kgf ・ m, 26 lb ・ ft) 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 35 N ・...
Page 152 FRONT WHEEL Disassembling the front wheel 2.0 N ・ m (0.20 kgf ・ m, 1.5 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 153: Removing The Front Wheel
FRONT WHEEL EAS30145 EAS30146 REMOVING THE FRONT WHEEL DISASSEMBLING THE FRONT WHEEL ECA20981 ECA21340 NOTICE NOTICE • Keep any type of magnets (including mag- • Do not drop the wheel sensor rotor or sub- netic pick-up tools, magnetic screwdrivers, ject it to shocks. etc.) away from the front wheel sensor or •...
Page 154: Assembling The Front Wheel
FRONT WHEEL Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) G088898 b. Install the spacer. c. Install the new wheel bearing (left side). Place a suitable washer “1” between the socket “2” and the bearing so that both the inner race G088897 “3”...
Page 155: Maintenance Of The Front Wheel Sensor And Sensor Rotor
FRONT WHEEL 4. Measure: • Wheel sensor rotor runout Out of specification  Correct the wheel sen- sor rotor runout or replace the wheel sensor rotor. Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-26. G088900 Wheel sensor rotor runout limit 3.
Page 156: Adjusting The Front Wheel Static Balance
FRONT WHEEL EAS30152 ADJUSTING THE FRONT WHEEL STATIC • The wheel sensor rotor is installed on the inner BALANCE side of the wheel hub. • When cleaning the wheel sensor rotor, be • After replacing the tire, wheel or both, the front careful not to damage the surface of the sensor wheel static balance should be adjusted.
Page 157 FRONT WHEEL ECA21020 NOTICE Apply lithium soap-based grease onto the mat- Make sure there are no foreign materials in ing surface of the front wheel axle bolt. the front wheel sensor rotor and front wheel sensor. Foreign materials cause damage to 5.
Page 158 FRONT WHEEL G088903 8. Install: • Front brake caliper • Front brake hose holder Front brake caliper bolt 35 N·m (3.5 kgf·m, 26 lb·ft) Front brake hose holder bolt (left) 9 N·m (0.9 kgf·m, 6.6 lb·ft) Front brake hose holder bolt (right) 7 N·m (0.7 kgf·m, 5.2 lb·ft) EWA13500...
Page 159: Rear Wheel
REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 160 N ・ m (16 kgf ・ m, 118 lb ・ ft) 16 N ・...
Page 160 REAR WHEEL Removing the rear brake disc and rear wheel pulley 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 64 N ・...
Page 161 REAR WHEEL Disassembling the rear wheel assembly Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing (left) Collar Wheel bearing (right) 4-32...
Page 162: Removing The Rear Wheel
REAR WHEEL EAS30910 REMOVING THE REAR WHEEL Push the rear wheel forward and remove the ECA21030 NOTICE drive belt from the rear wheel pulley. • Keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, EAS31154 DISASSEMBLING THE REAR WHEEL etc.) away from the rear wheel sensor or ECA21340 rear wheel sensor rotor;...
Page 163: Assembling The Rear Wheel
REAR WHEEL • Drive belt guide • Rear wheel sensor rotor Cracks/damage/wear  Replace the drive Refer to “ASSEMBLING THE FRONT belt guide. WHEEL” on page 4-25. 2. Replace: EAS30167 • Rear wheel pulley MAINTENANCE OF THE REAR WHEEL a. Remove the drive belt guide bolts and the SENSOR AND SENSOR ROTOR drive belt guide.
Page 164: Installing The Rear Wheel (Disc Brake)
REAR WHEEL EAS30165 INSTALLING THE REAR WHEEL (DISC • Tighten the rear wheel pulley bolts in stages BRAKE) and in a crisscross pattern. 1. Install: • When tightening the drive belt guide bolts, • Rear wheel sensor rotor tighten the bolt at the punch mark “a” first and •...
Page 165 REAR WHEEL 8. Tighten: • Wheel axle nut • Rear brake caliper bolt • Rear brake lock caliper bolt Rear wheel axle nut 160 N·m (16 kgf·m, 118 lb·ft) Rear brake caliper bolt 27 N·m (2.7 kgf·m, 20 lb·ft) Rear brake lock caliper bolt 23 N·m (2.3 kgf·m, 17 lb·ft) EWA13500 WARNING...
Page 166 REAR WHEEL G088906 11.Adjust: • Rear brake lock cable length To route the rear wheel sensor lead, refer to Refer to “ADJUSTING THE REAR BRAKE “CABLE ROUTING” on page 2-13. LOCK CABLE” on page 3-17. 10.Measure: • Distance “a” (between the rear wheel sensor rotor “1” and rear wheel sensor “2”) Out of specification ...
Page 167: Front Brake
FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 35 N ・ m (3.5 kgf ・ m, 26 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 35 N ・...
Page 168 FRONT BRAKE Removing the front brake master cylinder 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.0 N ・ m (0.10 kgf ・ m, 0.73 lb ・ ft) 6 N ・...
Page 169 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-40...
Page 170 FRONT BRAKE Removing the front brake calipers 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 35 N ・ m (3.5 kgf ・ m, 26 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 171 FRONT BRAKE Disassembling the front brake calipers 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 172: Introduction
FRONT BRAKE EAS30168 INTRODUCTION EWA14101 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary. • If any connection on the hydraulic brake G088908 system is disconnected, the entire brake 3.
Page 173 FRONT BRAKE 1. Remove: a. Connect a clear plastic hose “1” tightly to • Brake pad clip “1” the bleed screw “2”. Put the other end of the • Brake pad pin “2” hose into an open container. • Brake pad spring b.
Page 174: Removing The Front Brake Calipers
FRONT BRAKE 8. Check: c. Remove the brake caliper piston dust seals • Brake lever operation and brake caliper piston seals. Soft or spongy feeling  Bleed the brake sys- d. Repeat the previous steps to force out the tem. right side pistons from the brake caliper.
Page 175: Assembling The Front Brake Calipers
FRONT BRAKE EAS30174 ASSEMBLING THE FRONT BRAKE CALIPERS EWA16560 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents as they will cause the brake caliper piston dust seals and brake caliper piston seals to swell and distort.
Page 176: Removing The Front Brake Master Cylinder
FRONT BRAKE EWA13090 WARNING To collect any remaining brake fluid, place a • Use only the designated brake fluid. Other container under the master cylinder and the end brake fluids may cause the rubber seals to of the brake hose. deteriorate, causing leakage and poor brake performance.
Page 177 FRONT BRAKE • Install the front brake master cylinder holder Turn the handlebar to the left and right to make with the “ ” mark “a” facing up. sure the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if •...
Page 178 FRONT BRAKE 5. Check: • Brake fluid level Below the minimum level mark  Add the specified brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-14. 6. Check: • Brake lever operation Soft or spongy feeling  Bleed the brake sys- tem.
Page 179: Rear Brake
REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Rear brake caliper bolt Rear brake caliper Rear brake pad...
Page 180 REAR BRAKE Removing the rear brake master cylinder 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.0 N ・ m (0.10 kgf ・ m, 0.73 lb ・ ft) 6 N ・...
Page 181 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-52...
Page 182 REAR BRAKE Removing the rear brake caliper 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
Page 183 REAR BRAKE Disassembling the rear brake caliper 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw Brake caliper body 4-54...
Page 184 REAR BRAKE Removing the rear brake lock pads 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Rear brake lock cable adjusting nut Rear brake lock spring Rear brake lock caliper Rear brake lock pad 4-55...
Page 185 REAR BRAKE Removing the rear brake lock caliper 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Rear brake lock cable adjusting nut Rear brake lock spring Rear brake lock caliper 4-56...
Page 186 REAR BRAKE Disassembling the rear brake lock caliper 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 17 N ・...
Page 187: Introduction
REAR BRAKE EAS30183 INTRODUCTION Brake disc thickness limit EWA14101 4.5 mm (0.18 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...
Page 188: Removing The Rear Brake Caliper
REAR BRAKE EAS30186 a. Connect a clear plastic hose “1” tightly to REMOVING THE REAR BRAKE CALIPER the bleed screw “2”. Put the other end of the hose into an open container. Before removing the brake caliper, drain the brake fluid from the entire brake system. 1.
Page 189: Checking The Rear Brake Caliper
REAR BRAKE EAS30188 CHECKING THE REAR BRAKE CALIPER Specified brake fluid DOT 4 Recommended brake component replace- ment schedule EAS30190 Brake pads If necessary INSTALLING THE REAR BRAKE CALIPER 1. Install: Piston seal Every two years • Rear brake caliper “1” Piston dust seal Every two years (temporarily)
Page 190: Removing The Rear Brake Master Cylinder
REAR BRAKE Specified brake fluid To collect any remaining brake fluid, place a DOT 4 container under the master cylinder and the end of the brake hose. EWA13540 WARNING • Use only the designated brake fluid. Other EAS30194 CHECKING THE REAR BRAKE MASTER brake fluids may cause the rubber seals to CYLINDER deteriorate, causing leakage and poor...
Page 191: Installing The Rear Brake Master Cylinder
REAR BRAKE EAS30196 EWA13531 INSTALLING THE REAR BRAKE MASTER WARNING CYLINDER Proper brake hose routing is essential to in- 1. Install: sure safe vehicle operation. • Brake master cylinder “1” ECA14160 • Rear brake master cylinder holder “2” NOTICE When installing the brake hose onto the Brake master cylinder holder bolt brake master cylinder, make sure the brake 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Page 192: Replacing The Rear Brake Lock Pads
REAR BRAKE ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-16. 5. Check: • Brake fluid level a.
Page 193: Replacing The Rear Brake Lock Cable
REAR BRAKE 4. Adjust: • Rear brake lock cable length a. Adjust the clearance for the rear brake lock pad. Refer to “ADJUSTING THE REAR BRAKE LOCK CABLE” on page 3-17. b. Activate the rear brake lock cable 10 times. c.
Page 194: Assembling The Rear Brake Lock Caliper
REAR BRAKE EAS31421 ASSEMBLING THE REAR BRAKE LOCK CALIPER 1. Install: • Slide pin bolt “1” (to the rear brake lock caliper bracket) Rear brake lock caliper slide pin bolt 17 N·m (1.7 kgf·m, 13 lb·ft) 5. Install: • Shaft L “1” Recommended lubricant •...
Page 195: Installing The Rear Brake Lock Caliper
REAR BRAKE 7. Install: • Boot • Rear brake lock caliper arm • Check that the boot is installed correctly. • Install rear brake lock caliper arm “1” in the po- sition closest to cable holder “2”. 8. Install: • Rear brake lock adjusting nut •...
Page 196: Abs (Anti-Lock Brake System)
ABS (Anti-lock Brake System) EAS20032 ABS (Anti-lock Brake System) Removing the hydraulic unit assembly 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 197: Removing The Hydraulic Unit Assembly
ABS (Anti-lock Brake System) EAS30197 REMOVING THE HYDRAULIC UNIT ASSEMBLY ECA18230 NOTICE Unless necessary, avoid removing and in- stalling the brake pipes of the hydraulic unit assembly. EWA13930 WARNING Refill with the same type of brake fluid that is 2. Remove: already in the system.
Page 198: Checking The Hydraulic Unit Assembly
ABS (Anti-lock Brake System) EAS30198 CHECKING THE HYDRAULIC UNIT ASSEMBLY 1. Check: • Hydraulic unit assembly Cracks/damage  Replace the hydraulic unit assembly and the brake hoses that are con- nected to the assembly as a set. EAS30200 INSTALLING THE HYDRAULIC UNIT ASSEMBLY 4.
Page 199: Hydraulic Unit Operation Test
YDT sub harness (6P) (90890-03266). The hydraulic unit operation can be tested using • If you already have Yamaha diagnostic tool (A/ the following two methods. I) (90890-03262), YDT sub harness (6P) • Brake line routing confirmation: this test (90890-03266) is separately required.
Page 200 • Yamaha diagnostic tool (A/I) (90890-03264) in- sembly. cludes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/ 10.If the operation of the hydraulic unit is normal, I) (90890-03262), YDT sub harness (6P) delete all of the DTC.
Page 201 ABS (Anti-lock Brake System) 8. Click “Actuator Check”, and then operate the front brake lever “1” and rear brake lever “2” • The reaction-force pulsating action consists of simultaneously. quick pulses. • Be sure to continue operating the front brake •...
Page 202: Checking The Abs Warning Light
ABS (Anti-lock Brake System) 16.Check for brake fluid leakage around the hy- draulic unit. Brake fluid leakage  Replace the hydraulic unit, brake pipes, and related parts as a set. 17.If the operation of the hydraulic unit is normal, delete all of the DTC. EAS30202 CHECKING THE ABS WARNING LIGHT After all checks and servicing are completed, en-...
Page 203: Handlebar
HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar cover 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・...
Page 204 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) * YAMAHA GREASE “F” Order Job/Parts to remove Q’ty...
Page 205 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) * YAMAHA GREASE “F” Order Job/Parts to remove Q’ty...
Page 206 HANDLEBAR Removing the handlebar 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 7 N ・...
Page 207: Removing The Handlebar
HANDLEBAR EAS30203 REMOVING THE HANDLEBAR Lower handlebar holder nut 1. Stand the vehicle on a level surface. 34 N·m (3.4 kgf·m, 25 lb·ft) EWA13120 Upper handlebar holder bolt WARNING 23 N·m (2.3 kgf·m, 17 lb·ft) Securely support the vehicle so that there is no danger of it falling over.
Page 208 There should be 1–3 mm (0.04–0.12 in) of clear- ance “a” between the handlebar grip and the grip end. 6. Lubricate: • Rear brake lock cable (to cable end) Recommended lubricant YAMAHA GREASE “F” G088918 4-79...
Page 209: Adjusting The Accelerator Position Sensor
HANDLEBAR 10.Adjust: • Throttle grip free play Accelerator position sensor screw Refer to “CHECKING THE THROTTLE 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) GRIP” on page 3-33. Throttle grip free play 1.0–3.0 mm (0.04–0.12 in) 11.Adjust: • Rear brake lock cable length Refer to “ADJUSTING THE REAR BRAKE LOCK CABLE”...
Page 210: Front Fork
FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 14 N ・...
Page 211 FRONT FORK Disassembling the front fork legs 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 212: Removing The Front Fork Legs
FRONT FORK EAS30206 1. Remove: REMOVING THE FRONT FORK LEGS • Cap bolt “1” The following procedure applies to both of the • Spacer “2” front fork legs. • Damper rod locknut “3” 1. Stand the vehicle on a level surface. a.
Page 213: Checking The Front Fork Legs
FRONT FORK 3. Remove: • Damper rod assembly bolt • Damper rod assembly ECA17401 NOTICE For the damper rod assembly, the right side is used for the rebound operation and left side for the compression. Pay attention not to mistake the right and left. G088920 5.
Page 214: Assembling The Front Fork Legs
• Before assembling the front fork leg, make • Outer tube bushing “1” sure all of the components are clean. • Washer “2” 1. Lubricate: (with the fork seal driver “3”) • Inner tube outer surface Recommended oil Yamaha Suspension Oil 01 4-85...
Page 215 FRONT FORK 7. Install: Fork seal driver • Dust seal “1” 90890-01442 (with the fork seal driver “2”) Adjustable fork seal driver (36–46 mm) Fork seal driver YM-01442 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 G088923 5. Install: • Oil seal “1” (with the fork seal driver “2”) G088926 8.
Page 216 (with the specified amount of the recom- mended fork oil) While holding the damper rod assembly with the Recommended oil damper rod holder “2”, tighten the damper rod Yamaha Suspension Oil 01 assembly bolt. Quantity (left) 444.0 cm³ (15.01 US oz) Quantity (right) Damper rod holder (ø27)
Page 217 FRONT FORK 14.Measure: • Front fork leg oil level “a” Fork spring compressor 90890-01441 (from the top of the outer tube, with the outer Fork spring compressor tube fully compressed and without the fork YM-01441 spring) Out of specification  Correct. Rod holder 90890-01434 Damper rod holder double ended...
Page 218: Installing The Front Fork Legs
FRONT FORK EAS30210 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. Make sure the outer tube is flush with the top of the upper bracket.
Page 219: Steering Head
STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 52 N ・ m (5.2 kgf ・ m, 38 lb ・ ft) 130 N ・ m (13 kgf ・ m, 96 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 7 N ・...
Page 220 STEERING HEAD Removing the lower bracket 52 N ・ m (5.2 kgf ・ m, 38 lb ・ ft) 130 N ・ m (13 kgf ・ m, 96 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 7 N ・...
Page 221: Removing The Lower Bracket
STEERING HEAD EAS30213 a. Remove the bearing races from the steer- REMOVING THE LOWER BRACKET ing head pipe “1” with a long rod “2” and 1. Stand the vehicle on a level surface. hammer. EWA13120 b. Remove the bearing race from the lower WARNING bracket “3”...
Page 222 STEERING HEAD 2. Install: • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-23. G088935 3. Install: • Upper bracket • Washer •...
Page 223: Belt Drive
48 N ・ m (4.8 kgf ・ m, 35 lb ・ ft) 48 N ・ m (4.8 kgf ・ m, 35 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) * Filling the YAMAHA GREASE “J” (Shell Alvania EP Grease R0®). Order Job/Parts to remove Q’ty...
Page 224: Checking The Drive Belt
BELT DRIVE EAS30236 2. Lubricate: CHECKING THE DRIVE BELT • Drive pulley assembly inner part 1. Check: Refer to “LUBRICATING THE DRIVE PUL- • Drive belt LEY AND DRIVE AXLE” on page 3-22. Refer to “CHECKING THE DRIVE BELT” on 3.
Page 225: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 50 N ・ m (5.0 kgf ・ m, 37 lb ・ ft) 75 N ・ m (7.5 kgf ・ m, 55 lb ・ ft) 10 11 50 N ・...
Page 226: Handling The Rear Shock Absorber
REAR SHOCK ABSORBER ASSEMBLY EAS30826 HANDLING THE REAR SHOCK ABSORBER 50 mm (1.97 in) EWA13740 WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsi- ble for property damage or personal injury that may result from improper handling of...
Page 227: Checking The Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAS30220 CHECKING THE REAR SHOCK ABSORBER Installed depth “a” ASSEMBLY 7 mm (0.28 in) 1. Check: Installed depth “b” • Rear shock absorber rod 0.5–1.5 mm (0.02–0.06 in) Bends/damage  Replace the rear shock Installed depth “c” absorber assembly.
Page 228: Installing The Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY • When installing the oil seals “2” to the relay arm, face the character stamp of the oil seals outside. • Press in the oil seal so it does not protrude from the end surface of the relay arm. •...
Page 229: Swingarm
SWINGARM EAS20037 SWINGARM Removing the swingarm 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 6 N ・...
Page 230 SWINGARM Removing the swingarm 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 6 N ・...
Page 231: Removing The Swingarm
SWINGARM EAS30226 EAS30227 REMOVING THE SWINGARM CHECKING THE SWINGARM 1. Stand the vehicle on a level surface. 1. Check: EWA13120 • Swingarm (left) WARNING • Swingarm (right) Bends/cracks/damage  Replace. Securely support the vehicle so that there is no danger of it falling over. 2.
Page 232 SWINGARM Swingarm bolt 40 N·m (4.0 kgf·m, 30 lb·ft) Drive pulley assembly bolt 48 N·m (4.8 kgf·m, 35 lb·ft) 4. Tighten: • Pivot shaft • Pivot shaft nut Pivot shaft 6 N·m (0.6 kgf·m, 4.4 lb·ft) Pivot shaft nut 100 N·m (10 kgf·m, 74 lb·ft) a.
Page 233: Engine
ENGINE LUBRICATION SYSTEM CHART AND DIAGRAMS........5-1 ENGINE OIL LUBRICATION CHART ............5-1 LUBRICATION DIAGRAMS ..............5-2 ENGINE INSPECTION ..................5-6 MEASURE THE COMPRESSION PRESSURE........5-6 ENGINE REMOVAL ..................5-7 INSTALLING THE ENGINE..............5-11 CAMSHAFTS....................5-12 REMOVING THE CAMSHAFTS..............5-14 CHECKING THE CAMSHAFTS ..............5-14 CHECKING THE CAMSHAFT SPROCKETS .........5-16 CHECKING THE TIMING CHAIN GUIDES..........
Page 234 V-BELT AUTOMATIC TRANSMISSION ............5-39 REMOVING THE PRIMARY SHEAVE AND SECONDARY SHEAVE ....................5-43 DISASSEMBLY THE SECONDARY SHEAVE........5-43 CHECKING THE V-BELT................5-44 CHECKING THE PRIMARY SHEAVE ............5-44 CHECKING THE V-BELT CASE AIR DUCT ...........5-44 CHECKING THE PRIMARY SHEAVE WEIGHTS........5-44 CHECKING THE SLIDERS ..............5-44 CHECKING THE SECONDARY SHEAVE ..........
Page 235 CRANKCASE ....................5-66 ASSEMBLING THE CENTERSTAND .............5-70 DISASSEMBLING THE CRANKCASE............5-71 CHECKING THE CRANKCASE ..............5-71 CHECKING THE TIMING CHAIN............5-71 ASSEMBLING THE CRANKCASE............5-71 CRANKSHAFT ....................5-73 REMOVING THE CONNECTING RODS ..........5-75 REMOVING THE CRANKSHAFT JOURNAL BEARINGS ......5-75 CHECKING THE CRANKSHAFT AND CONNECTING RODS....5-75 INSTALLING THE CRANKSHAFT JOURNAL BEARINGS.....5-79 INSTALLING THE CONNECTING RODS..........
Page 236: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20298 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS32362 ENGINE OIL LUBRICATION CHART 1. Intake camshaft 15. Oil tank 2. Exhaust camshaft 16. Oil strainer 3. Timing chain tensioner 17. Feed pump 4. Connecting rod 18. Oil delivery pipe 5.
Page 237: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS32363 LUBRICATION DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Oil delivery pipe 4. Oil pump assembly 5. Scavenge pump 6. Feed pump 7. Oil pipe 8. Oil cooler 9. Oil filter 10. Engine oil check bolt 11.
Page 238 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Crankshaft 2. Secondary shaft 3. Drive axle 4. Clutch 5. Generator cover...
Page 239 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Intake camshaft 3. Exhaust camshaft...
Page 240 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Generator cover 2. Oil strainer 3. Main gallery 4. Crankcase (right) A. Forward...
Page 241: Engine Inspection
ENGINE INSPECTION EAS20041 7. Measure: ENGINE INSPECTION • Compression pressure Out of specification  Refer to steps (c) and (d). EAS30249 MEASURE THE COMPRESSION PRESSURE Compression pressure The following procedure applies to all of the cyl- 1653–2128 kPa/360 r/min inders. (16.5–21.3 kgf/cm²/360 r/min, 235.1–302.7 psi/360 r/min) Insufficient compression pressure will result in a...
Page 242: Engine Removal
ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the exhaust assembly 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 31 N ・...
Page 243 ENGINE REMOVAL Disconnecting the leads 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Windshield/Front cover/Rearview mirror/Wind- shield inner panel/Meter assembly/Bottom side Refer to “GENERAL CHASSIS (1)”...
Page 244 ENGINE REMOVAL Disconnecting the leads 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Swingarm Refer to “SWINGARM” on page 4-100. Air filter case/Throttle body assembly Refer to “THROTTLE BODY”...
Page 245 ENGINE REMOVAL Removing the engine 83 N · m (8.3 kgf · m, 61 lb · ft) 105 N · m (10.5 kgf · m, 77 lb · ft) 70 N · m (7.0 kgf · m, 52 lb · ft) 77 N ·...
Page 246: Installing The Engine
ENGINE REMOVAL EAS30251 INSTALLING THE ENGINE 1. Install: • All removed parts • Apply locking agent (LOCTITE®) to engine mounting bolt (front upper side) “1”, engine mounting bolt (front right lower side) “2”, en- gine mounting bolts (front left lower side) “3”, and rear frame bolts “5”.
Page 247: Camshafts
CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 10 N·m (1.0 kgf·m, 7.4 lb·ft) 13 N·m (1.3 kgf·m, 9.6 lb·ft) Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-27. Bottom side cowling/Side panel/Radiator cover/ Refer to “GENERAL CHASSIS (1)”...
Page 248 CAMSHAFTS Removing the camshafts 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Order Job/Parts to remove Q’ty Remarks Refer to “V-BELT AUTOMATIC TRANSMIS- Crankshaft end access cover SION”...
Page 249: Removing The Camshafts
CAMSHAFTS EAS30256 2. Remove: REMOVING THE CAMSHAFTS • Timing chain tensioner “1” 1. Align: • Timing chain tensioner gasket • “I” mark “a” on the generator rotor (with the stationary pointer “b” on the genera- tor cover) a. Turn the crankshaft clockwise. 3.
Page 250 CAMSHAFTS b. Position a strip of Plastigauge® “1” onto the Camshaft lobe dimensions camshaft journal as shown. Lobe height (Intake) 32.490–32.590 mm (1.2791–1.2831 in) Limit 32.390 mm (1.2752 in) Lobe height (Exhaust) 32.290–32.390 mm (1.2713–1.2752 in) Limit 32.190 mm (1.2673 in) G088947 c.
Page 251: Checking The Camshaft Sprockets
CAMSHAFTS Camshaft journal diameter 22.959–22.972 mm (0.9039–0.9044 in) EAS30266 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • Timing chain tensioner G088949 Cracks/damage/rough movement  Replace. EAS30936 CHECKING THE CAMSHAFT SPROCKETS a. Using the valve spring compressor “1”, The following procedure applies to both of the push and insert timing chain tensioner rod camshaft sprockets.
Page 252: Installing The Camshafts
CAMSHAFTS c. Push the timing chain tensioner rod “c”. c. Install the timing chain onto both camshaft d. If the circlip does not unlock even though sprockets, and then install the camshafts you press the timing chain tensioner rod in onto the cylinder head.
Page 253 CAMSHAFTS Make sure each camshaft cap is installed in its Push the timing chain tensioner rod in direction original place. Refer to the identification marks “a”, and turn the timing chain tensioner body “3” as follows: in direction “b” until the circlip fits into the groove. “IN”: Intake “EX”: Exhaust 3.
Page 254 CAMSHAFTS 9. Install: • Timing chain guide (upper side) • Cylinder head cover gasket (to the cylinder head cover) Apply Three bond No. 1541C “1” onto the mating surfaces of the cylinder head cover and gasket. 5. Turn: • Crankshaft (several turns clockwise) 6.
Page 255: Cylinder Head
CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head 15 N·m (1.5 kgf·m, 11 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 28 N·m (2.8 kgf·m, 21 lb·ft) 15 N·m (1.5 kgf·m, 11 lb·ft) *4th 6 N·m (0.6 kgf·m, 4.4 lb·ft) Specified angle 180˚...
Page 256: Removing The Cylinder Head
CYLINDER HEAD EAS30276 a. Place a straightedge “1” and a thickness REMOVING THE CYLINDER HEAD gauge “2” across the cylinder head. 1. Remove: • Cylinder head bolt Thickness gauge • Cylinder head nut 90890-03268 Feeler gauge set • Loosen the bolts and nuts in the proper se- YU-26900-9 quence as shown.
Page 257 CYLINDER HEAD Cylinder head nut 1st: 10 N·m (1.0 kgf·m, 7.4 lb·ft) 2nd: 20 N·m (2.0 kgf·m, 15 lb·ft) 3rd: 28 N·m (2.8 kgf·m, 21 lb·ft) *4th: 6 N·m (0.6 kgf·m, 4.4 lb·ft) Specified angle 180 Cylinder head bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Cylinder bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) * Following the tightening order, loosen the...
Page 258: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-20. Valve lifter Valve pad Valve cotter Valve spring retainer Valve spring Intake valve Exhaust valve Valve stem seal...
Page 259: Removing The Valves
VALVES AND VALVE SPRINGS EAS30283 REMOVING THE VALVES Valve spring compressor The following procedure applies to all of the 90890-04019 valves and related components. Valve spring compressor YM-04019 Before removing the internal parts of the cylinder Valve spring compressor attach- ment head (e.g., valves, valve springs, valve seats), 90890-04114...
Page 260 VALVES AND VALVE SPRINGS b. Install the new valve guide with the valve Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover ance (intake) “1”. 0.010–0.037 mm (0.0004–0.0015 Valve guide position (intake) Limit 12.2–12.6 mm (0.48–0.50 in) 0.080 mm (0.0032 in) Valve guide position (exhaust) Valve-stem-to-valve-guide clear- 12.2–12.6 mm (0.48–0.50 in)
Page 261: Checking The Valve Seats
VALVES AND VALVE SPRINGS 3. Eliminate: • Carbon deposit Valve seat contact width (intake) 0.90–1.10 mm (0.0354–0.0433 (from the valve face and valve seat) 4. Check: Limit • Valve face Pitting/wear  Grind the valve face. 1.6 mm (0.06 in) Valve seat contact width (ex- •...
Page 262: Checking The Valve Springs
VALVES AND VALVE SPRINGS g. Apply blue layout fluid “b” onto the valve a. Apply a coarse lapping compound “a” to the face. valve face. ECA13790 NOTICE Do not let the lapping compound enter the gap between the valve stem and the valve guide.
Page 263: Checking The Valve Lifters
VALVES AND VALVE SPRINGS • Make sure each valve is installed in its original place. • Install the valve springs with the larger pitch “a” facing up. G088971 EAS30287 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters.
Page 264 VALVES AND VALVE SPRINGS G088975 6. Lubricate: • Valve pad (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 7. Lubricate: • Valve lifter (with the recommended lubricant) Recommended lubricant Engine oil 8. Install: • Valve pad • Valve lifter ECA22150 NOTICE After making sure that the valve pads are ful-...
Page 265: Cylinder And Pistons
CYLINDER AND PISTONS EAS20046 CYLINDER AND PISTONS Removing the cylinder and pistons 10 N·m (1.0 kgf·m, 7.4 lb·ft) Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-20. Coolant hose Disconnect. Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin...
Page 266: Removing The Piston
CYLINDER AND PISTONS EAS30289 REMOVING THE PISTON The following procedure applies to all of the pis- ton. 1. Remove: • Piston pin clip • Piston pin “1” • Piston “2” ECA13810 NOTICE G088999 Do not use a hammer to drive the piston pin out.
Page 267: Checking The Piston Rings
CYLINDER AND PISTONS Piston ring Top ring Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) Side clearance limit 0.115 mm (0.0045 in) 2nd ring Ring side clearance G089001 0.020–0.055 mm a. 8.0 mm (0.31 in) from the bottom edge of (0.0008–0.0022 in) the piston Side clearance limit 0.115 mm (0.0045 in)
Page 268: Checking The Piston Pins
CYLINDER AND PISTONS G089003 G089005 4. Calculate: a. Bottom of cylinder • Piston-pin-to-piston-pin-bore clearance b. Upper of cylinder Out of specification  Replace the piston pin EAS30293 and piston as a set. CHECKING THE PISTON PINS The following procedure applies to both of the Piston-pin-to-piston-pin-bore clearance = Piston pin bore inside diameter - piston pins.
Page 269 CYLINDER AND PISTONS • Apply engine oil onto the piston pin. • Make sure the mark “a” on the piston points to- wards the exhaust side of the cylinder. • Reinstall each piston into its original cylinder. • Before installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crank- case.
Page 270: Electric Starter
ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 10 N m (1.0 kgf m, 7.4 lb • • • m (0.7 kgf m, 5.2 lb • • • Order Job/Parts to remove Q’ty Remarks Bottom side cowling/Side panel/Bottom center Refer to “GENERAL CHASSIS (1)”...
Page 271 ELECTRIC STARTER Disassembling the starter motor 11 N m (1.1 kgf m, 8.1 lb m (0.5 kgf m, 3.7 lb • • • • • • * When replacing any of the starter motor front cover, armature assembly, starter motor yoke, insulator, and starter motor rear cover, replace the starter motor assembly.
Page 272: Checking The Starter Motor
ELECTRIC STARTER EAS30325 4. Measure CHECKING THE STARTER MOTOR • Brush length “a” 1. Check: Out of specification  Replace the brush • Commutator holder set. Dirt  Clean with 600 grit sandpaper. 2. Measure: Brush overall length limit • Mica undercut “a” 6.5 mm (0.26 in) Out of specification ...
Page 273: Assembling The Starter Motor
ELECTRIC STARTER EAS30326 INSTALLING THE STARTER MOTOR ASSEMBLING THE STARTER MOTOR 1. Install: 1. Install: • Starter motor “1” • Insulator “1” • Starter motor lead “2” Install the insulator so that the slot “a” is posi- Connect the starter motor lead to the starter mo- tioned as shown in the illustration.
Page 274: V-Belt Automatic Transmission
V-BELT AUTOMATIC TRANSMISSION EAS20050 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case cover m (0.7 kgf m, 5.2 lb • • • 11 N m (1.1 kgf m, 8.1 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...
Page 275 • • 160 N m (16 kgf m, 118 lb • • • *1 Apply YAMAHA GREASE “G” (Shell Sunlight Grease 3®). *2 Apply YAMAHA GREASE “H” (Polyurea Grease®). Order Job/Parts to remove Q’ty Remarks Primary sheave nut Spacer O-ring...
Page 276 V-BELT AUTOMATIC TRANSMISSION Disassembling the primary sheave F W F W *1 Apply YAMAHA GREASE “F”. *2 When replacing the primary sliding sheave or collar, replace them as a set. Order Job/Parts to remove Q’ty Remarks Slider Primary sheave weight...
Page 277 Disassembling the secondary sheave 90 N m (9.0 kgf m, 66 lb • • • * Apply YAMAHA GREASE “H” (Polyurea Grease®). Order Job/Parts to remove Q’ty Remarks Secondary sheave spring seat nut Upper spring seat Secondary sheave compression spring...
Page 278: Removing The Primary Sheave And Secondary Sheave
V-BELT AUTOMATIC TRANSMISSION EAS31435 EAS30312 REMOVING THE PRIMARY SHEAVE AND DISASSEMBLY THE SECONDARY SHEAVE SECONDARY SHEAVE 1. Loosen: 1. Remove: • Secondary sheave spring seat nut “1” • Primary sheave nut “1” • Secondary sheave nut “2” • While holding the secondary fixed sheave “2” with the sheave holder “3”, loosen the second- While holding the primary and secondary ary sheave spring seat nut with the locknut...
Page 279: Checking The V-Belt
V-BELT AUTOMATIC TRANSMISSION EAS30317 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri- mary sheave weights. 1. Check: • Primary sheave weight Cracks/damage/wear  Replace. 2. Measure: • Primary sheave weight outside diameter Out of specification  Replace. EAS30315 CHECKING THE V-BELT Weight outside diameter...
Page 280: Assembling The Primary Sheave
• Oil seals • Primary sliding sheave inner surface (with the recommended lubricant) • Oil seal “1” Recommended lubricant (with the recommended lubricant) YAMAHA GREASE “H” (Polyurea Grease®) Recommended lubricant YAMAHA GREASE “F” 2. Install: • Guide pin Before installing the guide pin, align the position (where fixed sheave rivet head “a”...
Page 281 3. Lubricate: • Guide pin groove “1” • O-ring “2” (with the recommended lubricant) Recommended lubricant YAMAHA GREASE “H” (Poly- urea Grease®) 5. Tighten: • Secondary sheave spring seat nut “1” While holding the secondary fixed sheave “2” with the sheave holder “3”, tighten the second- ary sheave spring seat nut “1”...
Page 282: Installing The Primary Sheave Assembly, Secondary Sheave Assembly And V-Belt
• Sealant sembly then pass the V-belt the primary (onto the inner V-belt case seal) sheave side. • Align the “a” and “b” during reassembly. Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 4. Tighten: • Secondary sheave nut “1”...
Page 283: Installing The V-Belt Case
10 g (0.35 oz) or more of lithium-soap-based • Apply grease to the thread and seat of the grease. primary sheave nut. Recommended lubricant YAMAHA GREASE “G” (Shell Sunlight Grease 3®) While holding the primary sheave with the sheave holder “2”, tighten the primary sheave nut.
Page 284: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH EAS20140 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch (17) 10 N m (1.0 kgf m, 7.4 lb • • • 65 N·m (6.5 kgf·m, 48 lb·ft) Specified angle 120˚ 2nd Specified angle 120˚ 32 N m (3.2 kgf m, 24 lb...
Page 285 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch (17) 10 N m (1.0 kgf m, 7.4 lb • • • 65 N·m (6.5 kgf·m, 48 lb·ft) Specified angle 120˚ 2nd Specified angle 120˚ 32 N m (3.2 kgf m, 24 lb •...
Page 286 (1.2 kgf m, 8.9 lb • • • *1 When replacing the crankshaft position sensor or stator coil, replace them as a set. *2 Apply YAMAHA bond No. 1215 (Three bond No. 1215®). Order Job/Parts to remove Q’ty Remarks Oil tank...
Page 287: Removing The Generator
GENERATOR AND STARTER CLUTCH EAS30867 REMOVING THE GENERATOR Flywheel puller 1. Remove: 90890-01362 • Generator cover Heavy duty puller YU-33270-B Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
Page 288: Checking The Starter Clutch
GENERATOR AND STARTER CLUTCH EAS30869 CHECKING THE STARTER CLUTCH 1. Check: • Starter clutch roller Damage/wear  Replace the starter clutch. 2. Check: • Starter clutch idle gear • Starter clutch gear Burrs/chips/roughness/wear  Replace the defective part(s). 3. Check: EAS30871 •...
Page 289 • Lubricate the generator rotor nut seats and threads with engine oil. 3. Apply: • Sealant (onto the crankshaft position sensor/stator lead grommet) Yamaha bond No. 1215 90890-85505 2. Tighten: (Three bond No.1215®) • Generator rotor nut “1” Generator rotor nut (1st) 65 N·m (6.5 kgf·m, 48 lb·ft)
Page 290: Clutch
CLUTCH EAS20055 CLUTCH Removing the clutch 65 N m (6.5 kgf m, 48 lb • • • Order Job/Parts to remove Q’ty Remarks Bottom side cowling/Side panel/Bottom center Refer to “GENERAL CHASSIS (1)” on cowling page 4-1. Center cover/Fuel tank cover assembly/Side Refer to “GENERAL CHASSIS (2)”...
Page 291 CLUTCH Disassembling the clutch 130 N m (13 kgf m, 96 lb • • • Order Job/Parts to remove Q’ty Remarks Clip Spring stopper plate Clutch spring plate Pressure plate Clutch plate 2 Clutch damper spring Friction plate Clutch plate 1 Clutch spring Thrust plate Clutch boss nut...
Page 292 CLUTCH Disassembling the clutch 130 N m (13 kgf m, 96 lb • • • (12) Order Job/Parts to remove Q’ty Remarks Washer Clutch weight Clutch housing 5-57...
Page 293: Removing The Clutch
CLUTCH EAS30346 REMOVING THE CLUTCH 1. Remove: • Clutch assembly nut “1” • Clutch assembly “2” • Before removal, put alignment marks “a” and “b” as shown. • While holding the clutch assembly with the ro- tor holding tool “3”, loosen the clutch assembly 2.
Page 294: Checking The Friction Plates
CLUTCH EAS30348 CHECKING THE FRICTION PLATES Clutch plate 1 thickness The following procedure applies to all of the fric- 1.30–1.50 mm (00.51–0.059 in) tion plates. Warpage limit 1. Check: 0.10 mm (0.004 in) • Friction plate Clutch plate 2 thickness Damage/wear ...
Page 295: Checking The Clutch Spring Plate
CLUTCH EAS30350 EAS30353 CHECKING THE CLUTCH SPRING PLATE CHECKING THE CLUTCH BOSS 1. Check: 1. Check: • Clutch spring plate • Clutch boss spline Damage  Replace. Damage/pitting/wear  Replace the clutch 2. Measure: boss. • Clutch spring plate free height “a” Out of specification ...
Page 296: Installing The Clutch
CLUTCH While compressing the clutch springs with the clutch spring compressor “2”, install the clip. Clutch spring compressor 90890-01482 3. Install: • Clutch weight • Thrust plate “1” • Clutch spring • Clutch damper spring “2” • Clutch plate 2 “3” •...
Page 297 CLUTCH 5-62...
Page 298: Oil Pump
OIL PUMP EAS20054 OIL PUMP Removing the oil pump assembly 10 N m (1.0 kgf m, 7.4 lb • • • m (0.8 kgf m, 5.9 lb • • • Order Job/Parts to remove Q’ty Remarks Bottom side cowling/Side panel/Bottom center Refer to “GENERAL CHASSIS (1)”...
Page 299 OIL PUMP Disassembling the oil pump assembly m (0.6 kgf m, 4.4 lb • • • m (0.6 kgf m, 4.4 lb • • • * When replacing any of the part, replace the oil pump assembly. Order Job/Parts to remove Q’ty Remarks Oil pump housing 1...
Page 300: Checking The Oil Pump
OIL PUMP EAS30337 EAS30342 CHECKING THE OIL PUMP ASSEMBLING THE OIL PUMP 1. Check: 1. Lubricate: • Oil pump driven gear “1” • Inner rotor • Oil pump housing 2 “2” • Outer rotor • Oil pump housing 1 “3” •...
Page 301: Crankcase
CRANKCASE EAS20059 CRANKCASE Separating the crankcase 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 24 N·m (2.4 kgf·m, 18 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 43 N·m (4.3 kgf·m, 32 lb·ft) 55 N·m (5.5 kgf·m, 41 lb·ft) Order Job/Parts to remove Q’ty...
Page 302 CRANKCASE Separating the crankcase 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 24 N·m (2.4 kgf·m, 18 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 43 N·m (4.3 kgf·m, 32 lb·ft) 55 N·m (5.5 kgf·m, 41 lb·ft) Order Job/Parts to remove Q’ty...
Page 303 CRANKCASE Disassembling the Centerstand assembly 68 N m (6.8 kgf m, 50 lb • • • Order Job/Parts to remove Q’ty Remarks Spring Spring tube Centerstand bracket Centerstand 5-68...
Page 304 CRANKCASE Removing the oil seals and bearings 12 N m (1.2 kgf m, 8.9 lb • • • Order Job/Parts to remove Q’ty Remarks Crankshaft assembly Refer to “CRANKSHAFT” on page 5-73. Transmission Refer to “TRANSMISSION” on page 5-83. Bearing retainer Oil seal Bearing 5-69...
Page 305: Assembling The Centerstand
CRANKCASE EAS33379 a. Area where grease is prohibited ASSEMBLING THE CENTERSTAND 1. Clean: 4. Tighten: • Centerstand • Centerstand nut • Centerstand bracket • Centerstand bolt Centerstand nut 68 N·m (6.8 kgf·m, 50 lb·ft) • Centerstand nut ECA27050 5. Lubricate: NOTICE •...
Page 306: Disassembling The Crankcase
Work slowly and carefully • Sealant and make sure the crankcase halves sepa- (onto the crankcase mating surfaces) rate evenly. Yamaha bond No. 1215 EAS30390 90890-85505 CHECKING THE CRANKCASE (Three bond No.1215®) 1. Thoroughly wash the crankcase halves in a mild solvent.
Page 307 CRANKCASE 4. Install: • Dowel pin • Crankcase (left) 5. Install: • Crankcase bolt (M8) • Crankcase bolt (M6) Crankcase bolt (M8) 24 N·m (2.4 kgf·m, 18 lb·ft) Crankcase bolt (M6) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern.
Page 308: Crankshaft
CRANKSHAFT EAS20061 CRANKSHAFT Removing the crankshaft assembly 16 N·m (1.6 kgf·m, 12 lb·ft) 58 N ・ m 5.8 kgf ・ m, 43 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Dowel pin Balancer cylinder Crankshaft assembly Oil seal...
Page 309 CRANKSHAFT Removing the connecting rods 16 N m (1.6 kgf m, 12 lb • • • Specified angle 120˚ 60 N m (6.0 kgf m, 44 lb • • • 16 N m (1.6 kgf m, 12 lb • • •...
Page 310: Removing The Connecting Rods
CRANKSHAFT EAS30415 REMOVING THE CONNECTING RODS The following procedure applies to all of the con- necting rods. 1. Remove: • Connecting rod cap “1” • Connecting rod “2” • Big end bearing Identify the position of each big end bearing so that it can be reinstalled in its original place.
Page 311 CRANKSHAFT 3. Measure: • Crankshaft-pin-to-big-end-bearing clearance Out of specification  Replace the big end bearings. Connecting rod Oil clearance 0.039–0.063 mm (0.0015–0.0025 Balancer Balancer shaft journal to balanc- d. Assemble the connecting rod halves. er shaft bearing clearance 0.036–0.060 mm (0.0014–0.0024 •...
Page 312 CRANKSHAFT (connecting rod) - P (crankshaft) = 5 - 1 = 4 (green) Bearing color code Code 1 Blue Code 2 Black Code 3 4. Select: Brown • Big end bearings (P –P Code 4 Green • The numbers “A” stamped into the crankshaft web and the numbers “B”...
Page 313 CRANKSHAFT c. Measure the crankshaft journal diameter “a” of each crankshaft journal at two places. • The numbers “A” is stamped onto the crank- If it is out of specification, replace the crank- shaft web, the number “B” on the left crank- shaft.
Page 314: Installing The Crankshaft Journal Bearings
CRANKSHAFT For example, if the crankcase J and the crankshaft web J numbers are 4 and 2 re- spectively, then the bearing size for J (crankcase) - J (crankshaft web) = 4 - 2 = 2 (black) Bearing color code Code 0 White Code 1...
Page 315 CRANKSHAFT • Align the projections “a” on the big end bear- ings with the notches “b” in the connecting rods and connecting rod caps. • Be sure to reinstall each big end bearing in its original place. • Make sure the “Y” marks “c” on the connecting rods face towards the left side of the crank- shaft.
Page 316: Installing The Crankshaft Assembly
CRANKSHAFT 7. Install: • Balancer piston “1” • Align the projections “a” on the balancer big • Balancer piston pin end bearings with the notches “b” in the bal- • Piston pin clip “2” ancer connecting rod and balancer connecting rod cap.
Page 317 CRANKSHAFT 5-82...
Page 318: Transmission
TRANSMISSION EAS20062 TRANSMISSION Removing the transmission * Apply YAMAHA GREASE “J” (Shell Alvania EP Grease R0®). Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Secondary shaft Collar O-ring Primary driven gear Main axle 1st pinion gear...
Page 319: Checking The Transmission
TRANSMISSION EAS30433 CHECKING THE TRANSMISSION 1. Check: • Transmission gear Blue discoloration/pitting/wear  Replace. 2. Check: • Transmission gear movement Rough movement  Replace the defective part(s). 3. Check: • Main axle Cracks/damage/wear  Replace the main axle. 4. Measure: •...
Page 320 TRANSMISSION 5-85...
Page 321: Cooling System
COOLING SYSTEM COOLING SYSTEM DIAGRAMS ..............6-1 RADIATOR ...................... 6-3 CHECKING THE RADIATOR..............6-5 INSTALLING THE RADIATOR..............6-5 OIL COOLER....................6-7 CHECKING THE OIL COOLER ..............6-8 INSTALLING THE OIL COOLER .............. 6-8 THERMOSTAT ....................6-9 CHECKING THE THERMOSTAT............6-10 INSTALLING THE THERMOSTAT ASSEMBLY ........6-10 WATER PUMP....................6-11 DISASSEMBLING THE WATER PUMP..........
Page 322: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAS20299 COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator filler hose 3. Cooling system air bleed hose 4. Coolant reservoir hose 5. Radiator inlet hose 6. Thermostat 7. Oil cooler inlet hose 8. Oil cooler 9. Oil cooler outlet hose 10.
Page 323 COOLING SYSTEM DIAGRAMS 1. Thermostat 2. Cooling system air bleed hose 3. Coolant reservoir hose 4. Radiator cap 5. Radiator filler hose 6. Radiator 7. Radiator bracket 8. Radiator inlet hose 9. Oil cooler 10. Oil cooler inlet hose...
Page 324: Radiator
RADIATOR EAS20063 RADIATOR Removing the radiator 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 13 N ・...
Page 325 RADIATOR Removing the radiator 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 13 N ・...
Page 326: Checking The Radiator
RADIATOR EAS30439 CHECKING THE RADIATOR 1. Check: • Radiator fin Obstruction  Clean. Apply compressed air to the rear of the radia- tor. Damage  Repair or replace. Straighten any flattened fins with a thin, flathead G089029 b. Apply the specified pressure for ten sec- screwdriver.
Page 327 RADIATOR b. Apply 137.3 kPa (1.37 kgf/cm , 19.9 psi) of pressure. c. Measure the indicated pressure with the gauge.
Page 328: Oil Cooler
OIL COOLER EAS20064 OIL COOLER Removing the oil cooler 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Bottom side cowling/Side panel/Radiator cover/ Refer to “GENERAL CHASSIS (1)”...
Page 329: Checking The Oil Cooler
OIL COOLER EAS30441 4. Fill: CHECKING THE OIL COOLER • Cooling system 1. Check: (with the specified amount of the recom- • Oil cooler mended coolant) Cracks/damage  Replace. Refer to “CHANGING THE COOLANT” on 2. Check: page 3-31. • Oil cooler inlet hose •...
Page 330: Thermostat
THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Bottom side cowling/Side panel/Bottom center Refer to “GENERAL CHASSIS (1)” on cowling page 4-1. Center cover/Fuel tank cover assembly/Side Refer to “GENERAL CHASSIS (2)”...
Page 331: Checking The Thermostat
THERMOSTAT EAS30443 EAS30445 CHECKING THE THERMOSTAT INSTALLING THE THERMOSTAT 1. Check: ASSEMBLY • Thermostat 1. Install: Does not open at 82–95 C (179.6–203 F)  • Thermostat Replace. a. Suspend the thermostat “1” in a container Install the thermostat with its jiggle valve “a” “2”...
Page 332: Water Pump
WATER PUMP EAS20066 WATER PUMP Removing the water pump 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・...
Page 333 WATER PUMP Disassembling the water pump 10 N m (1.0 kgf m, 7.4 lb • • • Order Job/Parts to remove Q’ty Remarks Water pump housing cover Circlip Impeller shaft Mechanical seal Bearing Oil seal Water pump housing 6-12...
Page 334: Disassembling The Water Pump
WATER PUMP EAS30446 EAS30447 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Mechanical seal (impeller side) “1” • Water pump housing cover (from the impeller, with a thin, flathead screw- • Water pump housing driver) •...
Page 335: Installing The Water Pump
WATER PUMP EAS30449 INSTALLING THE WATER PUMP Mechanical seal installer (ø33) 1. Install: 90890-04132 • O-ring Water pump seal installer (ø33) • Water pump assembly YM-33221-A Middle driven shaft bearing driver 90890-04058 • Lubricate the impeller shaft with molybdenum Middle drive bearing installer disulfide grease.
Page 336 WATER PUMP 6-15...
Page 337: Fuel System
FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY............7-3 CHECKING THE FUEL PUMP OPERATION..........7-3 CHECKING THE ROLLOVER VALVE ............7-4 INSTALLING THE FUEL PUMP..............7-4 INSTALLING THE FUEL TANK..............7-4 THROTTLE BODY................... 7-5 CHECKING THE INJECTORS (BEFORE REMOVING) ......
Page 338 FUEL TANK EAS20067 FUEL TANK Removing the fuel tank 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) 4.0 N ・...
Page 339 FUEL TANK Removing the rollover valve and canister 7 N m (0.7 kgf m, 5.2 lb • • • Order Job/Parts to remove Q’ty Remarks Bottom side cowling/Side panel/Bottom center Refer to “GENERAL CHASSIS (1)” on cowling page 4-1. Center cover/Fuel tank cover assembly/Side Refer to “GENERAL CHASSIS (2)”...
Page 340: Fuel Tank
FUEL TANK EAS30450 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Bottom side cowling • Side panel • Bottom center cowling Refer to “GENERAL CHASSIS (1)” on page 4-1.
Page 341: Checking The Rollover Valve
FUEL TANK EAS30699 EAS30457 CHECKING THE ROLLOVER VALVE INSTALLING THE FUEL TANK 1. Check: 1. Connect: • Rollover valve “1” • Fuel hose (fuel tank side) Damage/faulty  Replace. ECA17500 NOTICE When installing the fuel hose, make sure that • Check that air flows smoothly only in the direc- it is securely connected, and that the fuel tion of the arrow shown in the illustration.
Page 342 THROTTLE BODY EAS20070 THROTTLE BODY Removing the air filter case 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 343 THROTTLE BODY Removing the throttle body 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 10 N ・...
Page 344: Throttle Body
THROTTLE BODY Removing the throttle body 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 345 THROTTLE BODY Disassembling the throttle body assembly 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Throttle position sensor Canister purge hose Hose joint...
Page 346: Checking The Injectors (Before Removing)
THROTTLE BODY EAS30475 EAS30476 CHECKING THE INJECTORS (BEFORE REMOVING THE INJECTORS REMOVING) EWA20210 WARNING 1. Check: • Check the injectors in a well-ventilated area • Injector free of combustible materials. Make sure Use the diagnostic code numbers “36”–“37”. that there is no smoking or use of electric Refer to “DIAGNOSTIC CODE: ACTUATOR tools in the vicinity of the injectors.
Page 347: Checking And Cleaning The Throttle Bodies
G089040 Recommended cleaning solvent d. Apply the recommended cleaning solvent Yamaha Oil & Brake Cleaner to the throttle valves and the inside of the throttle bodies to remove any carbon de- posits. 7-10...
Page 348: Replacing The Throttle Bodies
THROTTLE BODY 5. Adjust: • Throttle bodies synchronizing • Do not allow any cleaning solvent to enter the Out of specification  Replace the throttle opening for the injectors. bodies. • Do not apply any cleaning solvent to the por- Refer to “SYNCHRONIZING THE THROT- tions of the throttle valve shafts between the TLE BODIES”...
Page 349: Checking The Injector Pressure
THROTTLE BODY 4. Check the injector pressure after the injectors f. Close the valve on the fuel injector pressure are installed. adapter. Refer to “CHECKING THE INJECTOR g. Check that the specified air pressure is held PRESSURE” on page 7-12. at least one minute.
Page 350: Installing The Fuel Hose (Fuel Rail Side)
YDT to coupler. will not be properly installed. Refer to “YDT” on page 9-3. Yamaha diagnostic tool USB • Install the fuel hose securely onto the fuel rail 90890-03267 joint until a distinct “click” is heard.
Page 351 THROTTLE BODY • Yamaha diagnostic tool (A/I) (90890-03264) in- cludes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/ I) (90890-03262), YDT sub harness (6P) (90890-03266) is separately required. • For information about using the YDT, refer to the operation manual that is included with the tool.
Page 352 THROTTLE BODY 7-15...
Page 353: Electrical System
ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM .................. 8-1 TROUBLESHOOTING ................8-5 ELECTRIC STARTING SYSTEM ..............8-7 CIRCUIT DIAGRAM .................. 8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......8-11 TROUBLESHOOTING ................8-13 CHARGING SYSTEM..................8-17 CIRCUIT DIAGRAM ................8-17 TROUBLESHOOTING ................8-21 LIGHTING SYSTEM ..................8-23 CIRCUIT DIAGRAM ................
Page 354 SMART KEY SYSTEM .................. 8-67 CIRCUIT DIAGRAM ................8-67 TROUBLESHOOTING ................8-71 SMART KEY SYSTEM SELF-DIAGNOSIS..........8-78 SMART KEY SYSTEM EMERGENCY MODE ........8-80 REGISTERING A SMART KEY...............8-82 DISABLING A SMART KEY ..............8-84 REPLACING THE REMOTE CONTROL UNIT, STEERING LOCK, AND ECU ....................8-85 REPLACING THE REMOTE CONTROL UNIT ........
Page 356: Ignition System
IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM XP560E...
Page 357 IGNITION SYSTEM 2. Remote control unit 10. Joint coupler 11. Crankshaft position sensor 14. Ignition system relay 16. Ignition fuse 22. Battery 23. Engine ground 24. Main fuse 27. Diode 1 28. Sidestand relay 29. Diode 2 31. Starting circuit cut-off relay 32.
Page 358 IGNITION SYSTEM XP560D...
Page 359 IGNITION SYSTEM 2. Remote control unit 10. Joint coupler 11. Crankshaft position sensor 14. Ignition system relay 16. Ignition fuse 22. Battery 23. Engine ground 24. Main fuse 27. Diode 1 28. Sidestand relay 29. Diode 2 31. Starting circuit cut-off relay 32.
Page 360: Troubleshooting
IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Front cowling assembly/Side panels 2. Center cover 3. Footboards/Side covers 4. Rear side cowling assembly (right) 1. Check the fuses. (Main and ignition) NG...
Page 361 IGNITION SYSTEM 8. Check the diodes. (Diode 1 and diode 2) NG Replace the diode(s). Refer to “CHECKING THE DI- ODES” on page 8-101. OK 9. Check the starting circuit cut-off re- lay. NG Replace the starting circuit cut-off relay. Refer to “CHECKING THE RE- LAYS”...
Page 362: Electric Starting System
ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM XP560E...
Page 363 ELECTRIC STARTING SYSTEM 2. Remote control unit 10. Joint coupler 14. Ignition system relay 15. Signaling system fuse 16. Ignition fuse 22. Battery 23. Engine ground 24. Main fuse 25. Starter relay 26. Starter motor 28. Sidestand relay 29. Diode 2 31.
Page 364 ELECTRIC STARTING SYSTEM XP560D...
Page 365 ELECTRIC STARTING SYSTEM 2. Remote control unit 10. Joint coupler 14. Ignition system relay 15. Signaling system fuse 16. Ignition fuse 22. Battery 23. Engine ground 24. Main fuse 25. Starter relay 26. Starter motor 28. Sidestand relay 29. Diode 2 31.
Page 366: Starting Circuit Cut-Off System Operation
ELECTRIC STARTING SYSTEM EAS30494 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and pressing the ON/start switch for one second, the starter motor can only operate if at least one of the following conditions is met: •...
Page 367 ELECTRIC STARTING SYSTEM 1. Battery 2. Main fuse 3. Ignition system relay 4. Remote control unit 5. Signaling system fuse 6. Ignition fuse 7. Front brake light switch 8. Rear brake light switch 9. Diode 4 10. Starting circuit cut-off relay 11.
Page 368: Troubleshooting
ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank 4. Tail/brake light cover (right) 1. Check the fuses. (Main, ignition, brake light and sig- naling system) NG...
Page 369 ELECTRIC STARTING SYSTEM 8. Check the sidestand relay. Refer to “CHECKING THE RE- NG Replace the sidestand relay. LAYS” on page 8-94. OK 9. Check the starter relay. Refer to “CHECKING THE RE- NG Replace the starter relay. LAYS” on page 8-94. OK...
Page 370 ELECTRIC STARTING SYSTEM OK Replace the remote control unit. Refer to “SMART KEY SYSTEM” on page 8-67. 8-15...
Page 371 ELECTRIC STARTING SYSTEM 8-16...
Page 372: Charging System
CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM XP560E 8-17...
Page 373 CHARGING SYSTEM 10. Joint coupler 12. AC magneto 13. Rectifier/regulator 22. Battery 23. Engine ground 24. Main fuse A. Wire harness B. Negative battery sub-wire harness 8-18...
Page 374 CHARGING SYSTEM XP560D 8-19...
Page 375 CHARGING SYSTEM 10. Joint coupler 12. AC magneto 13. Rectifier/regulator 22. Battery 23. Engine ground 24. Main fuse A. Wire harness B. Negative battery sub-wire harness 8-20...
Page 376: Troubleshooting
CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank 4. Tail/brake light cover (right) 1. Check the fuse. (Main) NG Replace the fuse. Refer to “CHECKING THE FUS- ES”...
Page 377 CHARGING SYSTEM 8-22...
Page 378: Lighting System
LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM XP560E 8-23...
Page 379 LIGHTING SYSTEM 2. Remote control unit 7. Turn signal/hazard relay 8. Storage box light 10. Joint coupler 14. Ignition system relay 15. Signaling system fuse 16. Ignition fuse 17. Taillight fuse 21. Diode 3 22. Battery 23. Engine ground 24. Main fuse 40.
Page 380 LIGHTING SYSTEM XP560D 8-25...
Page 381 LIGHTING SYSTEM 2. Remote control unit 7. Turn signal/hazard relay 8. Storage box light 10. Joint coupler 14. Ignition system relay 15. Signaling system fuse 16. Ignition fuse 17. Taillight fuse 21. Diode 3 22. Battery 23. Engine ground 24. Main fuse 39.
Page 382: Troubleshooting
LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, auxiliary light, high beam indicator light, tail/brake light, li- cense plate light, meter light or storage box light. • Before troubleshooting, remove the following part(s): 1. Leg shield assembly 2.
Page 383 LIGHTING SYSTEM 8. Check the headlight relay (dim- mer). NG Replace the headlight relay (dimmer). Refer to “CHECKING THE RE- LAYS” on page 8-94. OK 9. Check the storage box light switch. Refer to “CHECKING THE NG Replace the storage box light switch. SWITCHES”...
Page 384: Signaling System
SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM XP560E 8-29...
Page 385 SIGNALING SYSTEM 2. Remote control unit 5. Buzzer 6. Steering lock relay 7. Turn signal/hazard relay 10. Joint coupler 14. Ignition system relay 15. Signaling system fuse 20. Backup fuse 22. Battery 23. Engine ground 24. Main fuse 32. Sidestand switch 34.
Page 386 SIGNALING SYSTEM XP560D 8-31...
Page 387 SIGNALING SYSTEM 2. Remote control unit 5. Buzzer 6. Steering lock relay 7. Turn signal/hazard relay 10. Joint coupler 11. Crankshaft position sensor 14. Ignition system relay 15. Signaling system fuse 20. Backup fuse 22. Battery 23. Engine ground 24. Main fuse 32.
Page 388: Troubleshooting
SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to operate. • The speedometer fails to operate. •...
Page 389 SIGNALING SYSTEM Checking the signaling system The horn fails to sound. 1. Check the horn switch. The horn switch is faulty. Replace the han- Refer to “CHECKING THE NG dlebar switch (left). SWITCHES” on page 8-91. OK 2. Check the entire signaling sys- tem’s wiring.
Page 390 SIGNALING SYSTEM 3. Check the turn signal/hazard relay. Refer to “CHECKING THE RE- NG Replace the turn signal/hazard relay. LAYS” on page 8-94. OK 4. Check the entire signaling sys- tem’s wiring. Properly connect or replace the wire har- NG Refer to “CIRCUIT DIAGRAM”...
Page 391 SIGNALING SYSTEM The speedometer fails to operate. 1. Check the rear wheel sensor. Refer to “MAINTENANCE OF THE NG Replace the rear wheel sensor. REAR WHEEL SENSOR AND SENSOR ROTOR” on page 4-34. OK 2. Check the entire wheel sensor wir- Properly connect or replace the wire har- ing.
Page 392 SIGNALING SYSTEM OK 2. Check the entire signaling system wiring. Properly connect or replace the wire har- NG Refer to “CIRCUIT DIAGRAM” on ness. page 8-29. OK Replace the ECU and/or meter as- sembly. The V-belt replacement indicator fails to come on. 1.
Page 393 SIGNALING SYSTEM 8-38...
Page 394: Cooling System
COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM XP560E 8-39...
Page 395 COOLING SYSTEM 2. Remote control unit 10. Joint coupler 14. Ignition system relay 16. Ignition fuse 18. Radiator fan motor fuse 20. Backup fuse 22. Battery 23. Engine ground 24. Main fuse 44. Meter assembly 56. Multi-function display 57. ECU (Engine Control Unit) 63.
Page 396 COOLING SYSTEM XP560D 8-41...
Page 397 COOLING SYSTEM 2. Remote control unit 10. Joint coupler 14. Ignition system relay 16. Ignition fuse 18. Radiator fan motor fuse 20. Backup fuse 22. Battery 23. Engine ground 24. Main fuse 55. Meter assembly 69. Multi-function display 70. ECU (Engine Control Unit) 76.
Page 398: Troubleshooting
COOLING SYSTEM EAS30503 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank 4. Footboard (right) 5. Rear side cowling assembly 1. Check the fuses. (Main, ignition, radiator fan motor and backup) NG...
Page 399 COOLING SYSTEM Replace the ECU and/or meter as- sembly. 8-44...
Page 400: Fuel Pump System
FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM XP560E 8-45...
Page 401 FUEL PUMP SYSTEM 2. Remote control unit 10. Joint coupler 14. Ignition system relay 16. Ignition fuse 19. Fuel injection system fuse 20. Backup fuse 22. Battery 23. Engine ground 24. Main fuse 30. Fuel injection system relay 34. Handlebar switch (right) 35.
Page 402 FUEL PUMP SYSTEM XP560D 8-47...
Page 403 FUEL PUMP SYSTEM 2. Remote control unit 10. Joint coupler 14. Ignition system relay 16. Ignition fuse 19. Fuel injection system fuse 20. Backup fuse 22. Battery 23. Engine ground 24. Main fuse 30. Fuel injection system relay 34. Handlebar switch (right) 35.
Page 404: Troubleshooting
FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank 1. Check the fuses. (Main, ignition, backup and fuel in- jection system) NG...
Page 405 FUEL PUMP SYSTEM 8-50...
Page 406: Windshield Drive System (For Xp560D)
WINDSHIELD DRIVE SYSTEM (for XP560D) EAS20083 WINDSHIELD DRIVE SYSTEM (for XP560D) EAS30517 CIRCUIT DIAGRAM 8-51...
Page 407 WINDSHIELD DRIVE SYSTEM (for XP560D) 2. Remote control unit 9. Windshield motor fuse 10. Joint coupler 14. Ignition system relay 16. Ignition fuse 20. Backup fuse 22. Battery 23. Engine ground 24. Main fuse 49. Windshield drive unit relay (down) 50.
Page 408: Troubleshooting
WINDSHIELD DRIVE SYSTEM (for XP560D) EAS30518 TROUBLESHOOTING The windshield fails to move. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Rear side cowling assembly 3. Leg shield 1. Check that there are no rocks or other foreign material in the wind- NG...
Page 409 WINDSHIELD DRIVE SYSTEM (for XP560D) OK 9. Check the windshield drive unit re- lay (down). Replace the windshield drive unit relay NG Refer to “CHECKING THE RE- (down). LAYS” on page 8-94. OK 10.Check the windshield drive motor. Refer to “CHECKING THE WIND- NG...
Page 410: Grip Warmer System (For Xp560D)
GRIP WARMER SYSTEM (for XP560D) EAS20167 GRIP WARMER SYSTEM (for XP560D) EAS31007 CIRCUIT DIAGRAM 8-55...
Page 411 GRIP WARMER SYSTEM (for XP560D) 2. Remote control unit 10. Joint coupler 14. Ignition system relay 16. Ignition fuse 20. Backup fuse 22. Battery 23. Engine ground 24. Main fuse 55. Meter assembly 69. Multi-function display 70. ECU (Engine Control Unit) 73.
Page 412: Troubleshooting
GRIP WARMER SYSTEM (for XP560D) EAS31008 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Rear side cowling assembly 3. Leg shield 4. Footboards The grip warmers do not become warm at all. 1. Check that the MIL is on and that Perform the troubleshooting for DTC No.
Page 413 GRIP WARMER SYSTEM (for XP560D) OK 9. Execute the diagnostic mode (code Replace the ECU. Refer to “REPLACING No. 57) to turn on the grip warmers, NG THE ECU (Engine Control Unit)” on and then check that they become page 8-93. warm.
Page 414 GRIP WARMER SYSTEM (for XP560D) OK Replace the meter assembly. 8-59...
Page 415 GRIP WARMER SYSTEM (for XP560D) 8-60...
Page 416: Seat Heater System (For Xp560D)
SEAT HEATER SYSTEM (for XP560D) EAS20312 SEAT HEATER SYSTEM (for XP560D) EAS32438 CIRCUIT DIAGRAM 8-61...
Page 417 SEAT HEATER SYSTEM (for XP560D) 2. Remote control unit 10. Joint coupler 14. Ignition system relay 15. Signaling system fuse 20. Backup fuse 22. Battery 23. Engine ground 24. Main fuse 52. Seat heater relay (control) 53. Seat heater relay (power) 54.
Page 418: Troubleshooting
SEAT HEATER SYSTEM (for XP560D) EAS32439 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Footboards 3. Rear side cowling assembly The seat heater does not become warm at all. 1. Check that the seat heater is not Adjust the temperature levels of the seat NG...
Page 419 SEAT HEATER SYSTEM (for XP560D) OK 9. Check the entire seat heater sys- tem wiring. Properly connect or replace the wiring har- NG Refer to “CIRCUIT DIAGRAM” on ness. page 8-61. OK Replace the meter assembly and/or ECU and/or remote control unit. The seat heater is abnormally hot while the engine is idling.
Page 420 SEAT HEATER SYSTEM (for XP560D) 4. Check the seat heater. Refer to “CHECKING THE SEAT NG Replace the seat assembly. HEATER (for XP560D)” on page 8- 110. OK Replace the meter assembly. The temperature levels of the seat heater settings cannot be changed. 1.
Page 421 SEAT HEATER SYSTEM (for XP560D) 8-66...
Page 422: Smart Key System
SMART KEY SYSTEM EAS20201 SMART KEY SYSTEM EAS31452 CIRCUIT DIAGRAM XP560E 8-67...
Page 423 SMART KEY SYSTEM 2. Remote control unit 3. OFF/LOCK switch 4. Parking/Unlock switch 5. Buzzer 6. Steering lock relay 7. Turn signal/hazard relay 8. Storage box light 9. Seat lock fuse 10. Joint coupler 14. Ignition system relay 15. Signaling system fuse 16.
Page 424 SMART KEY SYSTEM XP560D 8-69...
Page 425 SMART KEY SYSTEM 2. Remote control unit 3. OFF/LOCK switch 4. Parking/Unlock switch 5. Buzzer 6. Steering lock relay 7. Turn signal/hazard relay 8. Storage box light 9. Windshield motor fuse 10. Joint coupler 14. Ignition system relay 15. Signaling system fuse 16.
Page 426: Troubleshooting
SMART KEY SYSTEM EAS31453 TROUBLESHOOTING Vehicle power does not turn on. (Meter light and tail/brake light do not come on.) Engine does not start even though vehicle power is turned on. Seat/fuel lid or storage compartment lid (for XP560D) does not open. (Vehicle power is turned on.) Before troubleshooting, remove the following part(s): 1.
Page 427 SMART KEY SYSTEM Replace the remote control unit. 8-72...
Page 428 SMART KEY SYSTEM Checking the smart key system Before checking the smart key system, make sure that the smart key is located within the operating range of the smart key system and that the key is turned on. Vehicle power does not turn on. (Meter light and tail/brake light do not come on.) •...
Page 429 SMART KEY SYSTEM 5. The smart key system indicator light “ ” flashes. (The indicator light repeatedly Steering lock unit data error or malfunction flashes 3 times, and then goes off YES  Replace the steering lock unit. after approximately 20 seconds.) Refer to “SMART KEY SYSTEM SELF-DIAGNOSIS”...
Page 430 SMART KEY SYSTEM 2. Check the OFF/LOCK switch and Parking/Unlock switch. Replace the OFF/LOCK switch and/or NG Refer to “CHECKING THE Parking/Unlock switch. SWITCHES” on page 8-91. OK 3. Check that the smart key system indicator light “ ” flashes when the Communication between the remote con- Parking/Unlock switch on the vehi- trol unit and meter is not possible.
Page 431 SMART KEY SYSTEM NO • The storage compartment cannot be opened. • Check the mechanical components of the lock for malfunctions. Repair or replace any defective parts. • Check the storage compartment lid solenoid (for XP560D). Refer to “CHECKING THE STOR- AGE COMPARTMENT LID LOCK SOLENOID (for XP560D)”...
Page 432 SMART KEY SYSTEM 3. Check that the smart key system Communication between the remote con- indicator light “ ” flashes when the trol unit and centerstand lock unit is not ON/start switch on the vehicle is possible.  Check the wire harness (Light operated.
Page 433: Smart Key System Self-Diagnosis
SMART KEY SYSTEM EAS31534 SMART KEY SYSTEM SELF-DIAGNOSIS The smart key system is equipped with a self-diagnostic function. If a malfunction is detected in the sys- tem, the malfunction will be indicated by the flash pattern of the smart key system indicator light “ ”. The smart key system indicator light “...
Page 434 SMART KEY SYSTEM Flashing time/ Malfunction and Item Flash pattern number of flashes check point 20 (seconds)/flashes Check the wire har- 0.3 (s) 3 times in a repeating ness. • Steering lock data cycle Check the steering error lock unit. •...
Page 435: Smart Key System Emergency Mode
SMART KEY SYSTEM EAS31535 SMART KEY SYSTEM EMERGENCY MODE When the smart key is lost, damaged, or its battery has discharged, the vehicle can still be turned on and the engine started. You will need a mechanical key and the smart key system identification number. To operate the vehicle in emergency mode, carry out the following steps.
Page 436 SMART KEY SYSTEM 7. Inputting the identification number is done by counting the number of flashes of the smart key system indicator light “ ”. For example, if the identification number is 123456: Push and hold the Parking/Unlock switch.  The smart key system indicator light “...
Page 437: Registering A Smart Key
SMART KEY SYSTEM • If the identification number is not correctly entered, the smart key system indicator light “ ” will flash rapidly for 3 seconds and emergency mode is terminated. In this case, start over again from step (4). •...
Page 438 SMART KEY SYSTEM 5. While the smart key indicator light is on for 10 seconds, push the ON/OFF switch “ ” on the smart key to transmit a signal from the smart key to the remote control unit. 6. If the smart key is registered successfully, the smart key system indicator light “ ” will come on for 3 seconds, and then the smart key system will turn off.
Page 439: Disabling A Smart Key
SMART KEY SYSTEM EAS31537 DISABLING A SMART KEY If a smart key is lost or stolen, the smart key can be disabled. 1. Place all of the smart keys “1” 300 cm (118.1 in) “a” or more away from the vehicle or lock the com- munication.
Page 440: Replacing The Remote Control Unit, Steering Lock, And Ecu
SMART KEY SYSTEM EAS32446 REPLACING THE REMOTE CONTROL UNIT, STEERING LOCK, AND ECU The remote control unit, steering lock, and ECU cannot be replaced at the same time. EAS32447 REPLACING THE REMOTE CONTROL UNIT 1. Replace the remote control unit, and then place only 1 previously used smart key within 80 cm (31.5 in) of the remote control unit.
Page 441: Replacement Parts List
SMART KEY SYSTEM EAS31719 REPLACEMENT PARTS LIST When replacing the parts, refer to the following sections. • Refer to “SMART KEY SYSTEM EMERGENCY MODE” on page 8-80. • Refer to “REGISTERING A SMART KEY” on page 8-82. • Refer to “REPLACING THE REMOTE CONTROL UNIT, STEERING LOCK, AND ECU” on page 8- •...
Page 442 SMART KEY SYSTEM Required item when Replacement parts (when an item is required replacing parts in order to replace parts) ○ : Required. ○ : Replace. Smart key identifi- cation number or  : △ : Do not replace. smart key is Faulty part required.
Page 443: Electrical Components
ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 1. ECU (Engine Control Unit) 19. Ignition coil 2. Diode 2 20. Smart key system relay (unlock)/Smart key system relay (lock)/Headlight relay (dim- 3. Hydraulic unit assembly mer)/Brake light relay (for XP560D)/Fuel 4. Buzzer injection system relay/Steering lock relay/ 5.
Page 444 ELECTRICAL COMPONENTS 1. Fuel pump 2. Seat/fuel lid lock solenoid 3. Seat heater (for XP560D) 4. Storage box light switch 5. Sidestand relay/Turn signal/hazard relay/ Radiator fan motor relay/Seat heater relay (power) (for XP560D)/Seat heater relay (control) (for XP560D)/Windshield drive unit relay (down) (for XP560D)/Windshield drive unit relay (up) (for XP560D) 6.
Page 445 ELECTRICAL COMPONENTS 1. Front brake light switch (for XP560E) 19. Lean angle sensor 2. Front brake light switch (for XP560D) 20. Storage compartment lid lock solenoid (for XP560D) 3. Grip warmer (for XP560D) 21. Grip cancel switch 4. Parking/Unlock switch 5.
Page 446: Checking The Switches
ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Refer to “CHECKING THE SWITCHES” in “BASIC INFORMATION” (separate volume). XP560E B L/B B Br P...
Page 447 ELECTRICAL COMPONENTS XP560D Y/B O/W Br/L Y/B G/L G/W G/Y Y/B Y/W G/W G/Y Y/B Y/W R/B R/W L/W B PUSH FREE FREE Br/W Br/Y B/W W/G Y/W G/Y B L/B B Br P FREE PUSH PUSH FREE PASS Br/Y W/G B/W Br/W W/L B/W...
Page 448: Replacing The Ecu (Engine Control Unit)
ELECTRICAL COMPONENTS EAS30551 Amper- CHECKING THE FUSES Fuses Q’ty age rating The following procedure applies to all of the fus- ABS control unit 7.5 A ECA25770 ABS solenoid 15 A NOTICE Backup 15 A To avoid a short circuit, always push the OFF/LOCK switch when checking or replac- Auxiliary DC jack ing a fuse.
Page 449: Checking And Charging The Battery
ELECTRICAL COMPONENTS 9. Install: Engine idling speed • Battery band 1100–1300 r/min • Battery cover Refer to “GENERAL CHASSIS (1)” on EAS30552 page 4-1. CHECKING AND CHARGING THE BATTERY EAS30553 CHECKING THE RELAYS Refer to “CHECKING AND CHARGING THE Check each switch for continuity with the digital BATTERY”...
Page 450 ELECTRICAL COMPONENTS Starter relay Second step: G/R Br Y/B Br 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4. Negative tester probe 5.
Page 451 ELECTRICAL COMPONENTS Fuel injection system relay Turn signal/hazard relay Br/W 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4. Negative tester probe Result Result Continuity...
Page 452 ELECTRICAL COMPONENTS Ignition system relay Windshield drive unit relay (down) (for XP560D) First step: Br/L 1. Positive battery terminal 2. Negative battery terminal 1. Positive tester probe 3. Positive tester probe 2. Negative tester probe 4. Negative tester probe 3. Negative tester probe Result Result Continuity...
Page 453 ELECTRICAL COMPONENTS Windshield drive unit relay (up) (for XP560D) Seat heater relay (power) (for XP560D) First step: 1. Positive battery terminal 1. Positive tester probe 2. Negative battery terminal 2. Negative tester probe 3. Positive tester probe 3. Negative tester probe 4.
Page 454 ELECTRICAL COMPONENTS Second step: Result Continuity (between “1” and “2”) No continuity (between “1” and “3”) Second step: Y Br 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe Br/R R/G 4. Negative tester probe Result No continuity (between “3”...
Page 455 ELECTRICAL COMPONENTS Smart key system relay (lock) Second step: First step: Br/R Br/R 1. Positive battery terminal 2. Negative battery terminal 1. Positive tester probe 3. Positive tester probe 2. Negative tester probe 4. Negative tester probe 3. Negative tester probe 5.
Page 456: Checking The Diodes
ELECTRICAL COMPONENTS EAS30555 CHECKING THE DIODES Diode 1 1. Check: Continuity • Diode Positive tester probe  Out of specification  Replace. Green/Red, Blue/White “1” Negative tester probe  Digital circuit tester (CD732) Brown “2” 90890-03243 No continuity Positive tester probe  Model 88 Multimeter with tachometer Brown “2”...
Page 457: Checking The Spark Plug Caps
ELECTRICAL COMPONENTS When you switch the positive and negative tes- ter probes, the readings in the above chart will be reversed. EAS30557 CHECKING THE SPARK PLUG CAPS The following procedure applies to all of the spark plug caps. 1. Check: •...
Page 458: Checking The Ignition Spark Gap
ELECTRICAL COMPONENTS Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachometer YU-A1927 • Positive tester probe Orange “1” • Negative tester probe  Red/Black “2” c. Measure the secondary coil resistance. EAS30556 CHECKING THE IGNITION SPARK GAP 1. Check: •...
Page 459: Checking The Crankshaft Position Sensor
ELECTRICAL COMPONENTS EAS30560 CHECKING THE CRANKSHAFT POSITION Operating angle SENSOR 65  1. Disconnect: Output voltage up to operating • Crankshaft position sensor coupler angle (from the wire harness) 0.4–1.4 V 2. Check: Output voltage over operating • Crankshaft position sensor resistance angle Out of specification ...
Page 460: Checking The Starter Motor Operation
ELECTRICAL COMPONENTS EAS30562 • Positive tester probe  CHECKING THE STARTER MOTOR White “1” OPERATION • Negative tester probe  1. Check: White “2” • Starter motor operation Does not operate  Perform the electric • Positive tester probe  starting system troubleshooting, starting with White “1”...
Page 461: Checking The Fuel Sender
ELECTRICAL COMPONENTS b. Start the engine and let it run at approxi- mately 5000 r/min. c. Measure the rectifier/regulator input volt- age. EAS30573 CHECKING THE FUEL SENDER 1. Remove: • Fuel pump (from the fuel tank) Refer to “FUEL TANK” on page 7-1. c.
Page 462: Checking The Coolant Temperature Sensor
ELECTRICAL COMPONENTS • Positive battery terminal  Blue “1” Make sure the coolant temperature sensor • Negative battery terminal  terminals do not get wet. Black “2” c. Place a thermometer “3” in the coolant. G089056 d. Heat the coolant or let it cool down to the c.
Page 463: Checking The Accelerator Position Sensor
ELECTRICAL COMPONENTS a. Connect the digital circuit tester () to the Digital circuit tester (CD732) accelerator position sensor terminals as 90890-03243 shown. Model 88 Multimeter with tachometer Digital circuit tester (CD732) YU-A1927 90890-03243 Model 88 Multimeter with • Positive tester probe  tachometer Blue “1”...
Page 464: Checking The Windshield Drive Unit (For Xp560D)
ELECTRICAL COMPONENTS R Br A. Check that the throttle valves “2” fully close. A. Check that the windshield drive unit arms B. Check that the throttle valves “2” open. “2” up. B. Check that the windshield drive unit arms EAS32448 “2”...
Page 465: Checking The Seat Heater (For Xp560D)
ELECTRICAL COMPONENTS • Positive tester probe  EAS30593 CHECKING THE INTAKE AIR PRESSURE Black “1” SENSOR • Negative tester probe  1. Check: Black “2” • Intake air pressure sensor output voltage Out of specification  Replace. Atmospheric pressure sensor output voltage 3.59–3.67 V at 101.3 kPa (3.59–3.67 V at 1.01 kgf/cm²,...
Page 466: Checking The Intake Air Temperature Sensor
ELECTRICAL COMPONENTS EAS30594 e. Measure the intake air temperature sensor CHECKING THE INTAKE AIR resistance. TEMPERATURE SENSOR 3. Install: 1. Remove: • Intake air temperature sensor • Intake air temperature sensor EWA14110 WARNING Intake air temperature sensor • Handle the intake air temperature sensor screw 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) with special care.
Page 467: Checking The Smart Key Battery
ELECTRICAL COMPONENTS EAS31553 CHECKING THE SMART KEY BATTERY 1. Check: • Smart key battery voltage Out of specification  Replace the smart key battery. Smart key battery voltage 2.4–3.2 V a. Remove the smart key battery from the c. Check that the buzzer sounds. smart key.
Page 468 ELECTRICAL COMPONENTS c. Check the storage compartment lid lock so- lenoid movement. 8-113...
Page 469: Self Diagnostic
SELF DIAGNOSTIC SELF-DIAGNOSTIC FUNCTION..............9-1 GLOSSARY....................9-1 OUTLINE ....................9-1 CHECKING THE WARNING LIGHT ............9-2 YDT ......................9-3 PARTS CONNECTED TO THE ECU ............9-3 PARTS CONNECTED TO THE ABS ECU..........9-4 PRECAUTIONS FOR ROAD TEST ............9-4 SYSTEM DIAGRAM ..................9-5 ECU CIRCUIT DIAGRAM................9-5 ECU COUPLER LAYOUT .................
Page 470 [A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE ......9-36 [B-1] MALFUNCTION ARE CURRENTLY DETECTED ......9-36 [B-2] DIAGNOSIS USING THE DTC ............9-36 [B-3] DELETING THE DTC ..............9-37 [C-1] FINAL CHECK ................9-37 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE..9-38 DTC TABLE.....................
Page 471 P0201......................9-98 TROUBLESHOOTING ................9-98 P0202......................9-101 TROUBLESHOOTING ................9-101 P0335......................9-104 TROUBLESHOOTING ................9-104 P0351......................9-108 TROUBLESHOOTING ................9-108 P0480......................9-112 TROUBLESHOOTING ................9-112 P0500......................9-115 TROUBLESHOOTING ................9-115 P0507......................9-119 TROUBLESHOOTING ................9-119 P0560, P0563 ....................9-121 TROUBLESHOOTING ................9-121 P0564......................9-122 TROUBLESHOOTING ................9-122 P056C ......................9-128 TROUBLESHOOTING ................9-128 P0601......................9-136 TROUBLESHOOTING ................9-136 P0606......................9-137 TROUBLESHOOTING ................9-137 P062F ......................9-138 TROUBLESHOOTING ................9-138 P0638......................9-140...
Page 472 P0657......................9-144 TROUBLESHOOTING ................9-144 P1601......................9-148 TROUBLESHOOTING ................9-148 P1602......................9-152 TROUBLESHOOTING ................9-152 P1604, P1605 ....................9-155 TROUBLESHOOTING ................9-155 P2122, P2123, P2127, P2128, P2138 ............9-158 TROUBLESHOOTING ................9-158 P2158......................9-162 TROUBLESHOOTING ................9-162 U0155 or Err....................9-166 TROUBLESHOOTING ................9-166 11, 25_ABS ....................9-169 TROUBLESHOOTING ................9-169 12_ABS .......................9-170 TROUBLESHOOTING ................9-170...
Page 473 18, 46_ABS ....................9-178 TROUBLESHOOTING ................9-178 21_ABS .......................9-179 TROUBLESHOOTING ................9-179 24_ABS .......................9-180 TROUBLESHOOTING ................9-180 31_ABS .......................9-184 TROUBLESHOOTING ................9-184 32_ABS .......................9-186 TROUBLESHOOTING ................9-186 33_ABS .......................9-187 TROUBLESHOOTING ................9-187 34_ABS .......................9-189 TROUBLESHOOTING ................9-189 41_ABS .......................9-190 TROUBLESHOOTING ................9-190 42, 47_ABS ....................9-191 TROUBLESHOOTING ................9-191 43_ABS .......................9-192 TROUBLESHOOTING ................9-192 44_ABS .......................9-193 TROUBLESHOOTING ................9-193...
Page 474 55_ABS .......................9-199 TROUBLESHOOTING ................9-199 56_ABS .......................9-200 TROUBLESHOOTING ................9-200 63_ABS .......................9-201 TROUBLESHOOTING ................9-201 64_ABS .......................9-203 TROUBLESHOOTING ................9-203...
Page 475: Self-Diagnostic Function
Generic diagnostic tool that complies with OBD standards. (Generic scan tool) (Yamaha diagnostic Diagnostic tool developed especially for Yamaha vehicles. tool) EAS32858 OUTLINE The control unit is equipped with a self-diagnostic function in order to ensure that the system is operat- ing normally.
Page 476: Checking The Warning Light
SELF-DIAGNOSTIC FUNCTION EAS32859 CHECKING THE WARNING LIGHT The warning light comes on after the ON/start switch has been pushed on. Refer to the following table for lighting up time. If the warning light still comes on, refer to a check item of a troubleshooting of each system, check and repair it.
Page 477: Ydt
90890-03264 • Yamaha diagnostic tool (A/I) (90890-03264) includes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890- 03266) is separately required. • A GST can also be used to identify malfunctions.
Page 478: Parts Connected To The Abs Ecu
SELF-DIAGNOSTIC FUNCTION EAS32918 PARTS CONNECTED TO THE ABS ECU The following parts are connected to the hydraulic unit assembly (ABS ECU). When checking for a power short circuit, the couplers must be disconnected from all of the following parts beforehand. •...
Page 479: System Diagram
SYSTEM DIAGRAM EAS20387 SYSTEM DIAGRAM EAS32920 ECU CIRCUIT DIAGRAM 7. Electronic throttle valve fuse 40. Injector #1 18. Fuel 14. Fuel injection 41. Injector #2 injection 8. Ignition system system system relay fuse relay 15. Engine 19. Fuel 13. Ignition stop pump fuse...
Page 480 SYSTEM DIAGRAM 45. Grip 46. Grip warmer warmer 37. Throttle (left) (right) position sensor 37. Throttle position sensor 1. ECU (Engine Control Unit) 47. Radiator fan motor relay 38. Accelerator position sensor 38. Accelerator position Headlight sensor Dimmer Pass control switch switch unit...
Page 481 SYSTEM DIAGRAM 1. ECU (Engine Control Unit) 2. Battery 3. Main fuse 4. Starter relay 5. Starter motor 6. Front brake light switch 7. Electronic throttle valve fuse 8. Ignition system relay 9. Signaling system fuse 10. Rear brake light switch 11.
Page 482: Ecu Coupler Layout
SYSTEM DIAGRAM EAS33369 ECU COUPLER LAYOUT 1 2 3 4 5 6 7 8 9 35 36 37 38 39 40 41 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 10 11 12 13 14 15 16 17 42 43 44 45 46 47 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 18 19 20 21 22 23 24 25...
Page 483 SYSTEM DIAGRAM Wire harness Wire harness Connected parts Connected parts color color — — Crankshaft position sensor — — Joint coupler Lg/L — — — — — — — — — — — — Throttle position sensor — — — —...
Page 484 SYSTEM DIAGRAM Wire harness Connected parts color ABS ECU (Electron- ic Control Unit) — — 9-10...
Page 485 SYSTEM DIAGRAM 9-11...
Page 486: Fuel Injection System
FUEL INJECTION SYSTEM EAS20440 FUEL INJECTION SYSTEM EAS32871 CIRCUIT DIAGRAM XP560E 9-12...
Page 487 FUEL INJECTION SYSTEM 2. Remote control unit 10. Joint coupler 11. Crankshaft position sensor 14. Ignition system relay 15. Signaling system fuse 16. Ignition fuse 18. Radiator fan motor fuse 19. Fuel injection system fuse 20. Backup fuse 22. Battery 23.
Page 488 FUEL INJECTION SYSTEM XP560D 9-14...
Page 489 FUEL INJECTION SYSTEM A. Wire harness 2. Remote control unit 10. Joint coupler B. Negative battery sub-wire harness 11. Crankshaft position sensor C. Headlight sub-wire harness 14. Ignition system relay 15. Signaling system fuse 16. Ignition fuse 18. Radiator fan motor fuse 19.
Page 490: Basic Process For Troubleshooting
FUEL INJECTION SYSTEM EAS32917 BASIC PROCESS FOR TROUBLESHOOTING This section describes the basic process about fuel injection system troubleshooting. But because a work procedure varies depending to symptom and DTC, check and repair it according to applicable troubleshooting. When pushing the ON/start switch, Does the MIL (LED) work Check the MIL (LED).
Page 491: [A] The Mil Comes On/Flashes And Engine Operation Is Not Normal
FUEL INJECTION SYSTEM EAS33147 [A] THE MIL COMES ON/FLASHES AND ENGINE OPERATION IS NOT NORMAL 1. Check the DTC of “malfunction” using the YDT. 2. Delete the DTC using the YDT. (Only for *1) 3. Check and repair the malfunction according to applicable DTC troubleshooting. 4.
Page 492: Cruise Control System (For Xp560D)
CRUISE CONTROL SYSTEM (for XP560D) EAS20441 CRUISE CONTROL SYSTEM (for XP560D) EAS32875 CIRCUIT DIAGRAM XP560D 9-18...
Page 493 CRUISE CONTROL SYSTEM (for XP560D) 2. Remote control unit 10. Joint coupler 14. Ignition system relay 15. Signaling system fuse 16. Ignition fuse 20. Backup fuse 22. Battery 23. Engine ground 24. Main fuse 41. Brake light fuse 42. Front brake light switch 43.
Page 494: Cruise Control Circuit Operation
CRUISE CONTROL SYSTEM (for XP560D) EAS32876 CRUISE CONTROL CIRCUIT OPERATION 8. Ignition 9. Cruise control 10.Cruise control fuse system fuse power switch 11.Cruise control setting switch 14.Grip 12.Front brake 13.Rear brake 17.ECU (Engine cancel light switch light switch Control Unit) switch 6.
Page 495: Basic Instructions For Troubleshooting
CRUISE CONTROL SYSTEM (for XP560D) EAS32877 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 1. Check the DTC of “malfunction” using the YDT. 2. Check and repair the malfunction according to applicable DTC troubleshooting. 3. Push the OFF/LOCK switch, and then push the ON/start switch, and then check the DTC of “mal- function”...
Page 496: Basic Process For Troubleshooting
CRUISE CONTROL SYSTEM (for XP560D) EAS32878 BASIC PROCESS FOR TROUBLESHOOTING When pushing the ON/start Check the MIL (LED). switch, does the MIL come on? The MIL goes off after 2 seconds? Fails to come on Push the cruise control The cruise control power switch is •...
Page 497: [A] Checking The Cruise Control System Indicator Light
CRUISE CONTROL SYSTEM (for XP560D) EAS32879 [A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT Push the ON/start switch, and then push the cruise control power switch. 1. The cruise control system indicator light does not come on. • Check the control power switch for continuity. Refer to “CHECKING THE SWITCHES” on page 8- 91.
Page 498 CRUISE CONTROL SYSTEM (for XP560D) Automatic deactivation of the cruise control system The cruise control system is electronically controlled and linked with other control systems. The cruise control system will automatically deactivate under the following conditions: • The cruise control system is not able to maintain the set cruising speed (such as when going up a steep hill).
Page 499: [C-1] Erasing The Dtc
CRUISE CONTROL SYSTEM (for XP560D) EAS32883 [C-1] ERASING THE DTC 1. Delete the DTC using the malfunction of the YDT, and check that the MIL goes off. EAS32884 [C-2] FINAL CHECK EWA17441 WARNING When maintenance or checks have been performed on components related to the cruise control system, be sure to perform a final check before delivering the vehicle to the customer.
Page 500: Abs (Anti-Lock Brake System)
ABS (Anti-lock Brake System) EAS20443 ABS (Anti-lock Brake System) EAS32890 CIRCUIT DIAGRAM XP560E 9-26...
Page 501 ABS (Anti-lock Brake System) 2. Remote control unit 10. Joint coupler 14. Ignition system relay 15. Signaling system fuse 16. Ignition fuse 20. Backup fuse 22. Battery 23. Engine ground 24. Main fuse 34. Handlebar switch (right) 39. Front brake light switch 40.
Page 502 ABS (Anti-lock Brake System) XP560D 9-28...
Page 503 ABS (Anti-lock Brake System) 2. Remote control unit 10. Joint coupler 14. Ignition system relay 15. Signaling system fuse 16. Ignition fuse 20. Backup fuse 22. Battery 23. Engine ground 24. Main fuse 39. Headlight relay (dimmer) 40. Brake light relay 41.
Page 504: Abs Components Chart
ABS (Anti-lock Brake System) EAS32891 ABS COMPONENTS CHART 1. YDT coupler 2. ABS warning light 3. Fuse box (ABS motor fuse, ABS solenoid fuse, and ABS ECU fuse) 4. ABS ECU 5. Front wheel sensor rotor 6. Front wheel sensor 7.
Page 505: Abs Coupler Location Chart
ABS (Anti-lock Brake System) EAS32892 ABS COUPLER LOCATION CHART O/L R/L Br/Y Ch Dg R/GR/W Gy V Gy/W V/W G/R G/L G W/G W/R W/L Y B/W Lg/WLg/L B/W R/GR/G (Gy) P/W P/B O/L R/L B/W Br/Y L/R Br/Y Ch Dg R/GR/W Gy V Gy/W V/W G/R G/L G W/G W/R W/L Y B/W Lg/W Lg/L B/W R/GR/G (Gy)
Page 506: Maintenance Of The Abs Ecu
ABS (Anti-lock Brake System) EAS32893 MAINTENANCE OF THE ABS ECU Checking the ABS ECU 1. Check: • Terminals “1” of the hydraulic unit assembly (ABS ECU) Cracks/damages  Replace the hydraulic unit assembly, brake hoses, and brake pipes that are connected to the assembly as a set.
Page 507: Basic Instructions For Troubleshooting
ABS (Anti-lock Brake System) Self-diagnosis with the ABS ECU The ABS ECU performs a static check of the entire system when the ON/start switch is pushed. It also checks for malfunctions while the vehicle is ridden. Since all malfunctions are recorded after they are detected, it is possible to check the recorded malfunction data by utilizing the YDT when the ABS ECU has entered the self-diagnosis mode.
Page 508 ABS (Anti-lock Brake System) Fails to Push the ON/start switch, • The ABS warning light (LED) is [A-1] Does only the ABS come on and check the ABS warning Return to [A]. defective. warning light fail to light. come on? •...
Page 509: [A] Checking The Abs Warning Light
ABS (Anti-lock Brake System) EAS32897 [A] CHECKING THE ABS WARNING LIGHT Push the ON/start switch to “ON”. (Do not start the engine.) 1. The ABS warning light does not come on. • Only the ABS warning light fails to come on. [A-1] •...
Page 510 90890-03264 • Yamaha diagnostic tool (A/I) (90890-03264) includes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890- 03266) is separately required. Details about the displayed DTCs are shown in the following chart. Refer to this chart and check the ve- hicle.
Page 511 Yamaha diagnostic tool (A/I) 90890-03264 • Yamaha diagnostic tool (A/I) (90890-03264) includes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890- 03266) is separately required. EAS32905 [C-1] FINAL CHECK...
Page 512 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS20551 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33149 DTC TABLE Fail-safe system Diagnostic Symptom Starting the Driving the code engine vehicle “11, Front wheel sensor (intermittent pulses — — — 25_ABS” or no pulses) Rear wheel sensor (intermittent pulses or “12_ABS”...
Page 513 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnostic Symptom Starting the Driving the code engine vehicle Vehicle system power supply (voltage of “53_ABS” — — — ABS ECU power supply is low) Hydraulic unit assembly (defective ABS “54_ABS” solenoid and ABS motor power supply —...
Page 514 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnostic Symptom Starting the Driving the code engine vehicle Able Able (depending (depending “P0201” Injector #1: malfunction in injector #1. on the num- on the num- ber of faulty ber of faulty cylinders) cylinders) Able...
Page 515 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnostic Symptom Starting the Driving the code engine vehicle Sidestand switch: open or short circuit of “P1601” the light green lead of the ECU is detect- Unable Unable Malfunction in ECU internal circuit (mal- “P1602”...
Page 516 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33028 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM) For details of the DTC, refer to “BASIC PROCESS FOR TROUBLESHOOTING” on page 9-16. Probable cause of Fail-safe system Item Vehicle symptom malfunction operation Latch up detected. •...
Page 517 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed Intake air pressure P0108 pressure sensor: of the intake air is unstable. is fixed to 101.3 ground short circuit pressure sensor cir- Engine response is...
Page 518 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0117 [P0117] Coolant [P0117] Low voltage Engine is difficult to The radiator fan mo- P0118 temperature sensor: of the coolant tem- start. tor relay is on only ground short circuit perature sensor cir- Increased exhaust...
Page 519 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0122 [P0122] Throttle po- [P0122, P0222] Low Engine idling speed Change in the throt- P0123 sition sensor: voltage of the throt- is high. tle opening is 0 P0222 ground short circuit tle position sensor...
Page 520 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0201 [P0201] Injector #1: feedback is not • Defective coupler Loss of engine pow- P0202 malfunction in injec- between injector carried out. tor #1. and ECU.
Page 521 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0480 Radiator fan motor • Open or short cir- Engine is difficult to Radiator fan motor relay: open or short cuit in wire har- start.
Page 522 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0563 Vehicle system • Battery overcharg- feedback is not Engine is difficult to power voltage out of ing (defective rec- start. carried out. range tifier/regulator).
Page 523 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0606 Internal malfunction • Malfunction in Engine cannot be Engine cannot be in ECU. (When this ECU. started. started. malfunction is de- Engine response is Ignition and injec- tected in the ECU, poor.
Page 524 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0638 YCC-T drive sys- • Defective coupler feedback is not Engine response is tem: malfunction de- between throttle poor. carried out. tected. servo motor and Loss of engine pow- YCC-T evacuation ECU.
Page 525 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P1602 Malfunction in ECU • Open or short cir- feedback learn- Engine idling speed internal circuit (mal- cuit in wire har- is unstable. ing is not carried function of ECU ness between Engine idling speed...
Page 526 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P2122 [P2122] Accelerator [P2122, P2127] Low Engine response is No change in accel- P2123 position sensor: voltage of the accel- poor. erator opening P2127 open or ground erator position sen- Loss of engine pow-...
Page 527 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33286 SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS (Anti-lock Brake System)) For details of the DTC, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-33. Item Symptom Check point Front wheel sensor (inter- Front wheel sensor signal •...
Page 528 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Front wheel sensor (open Open or short circuit is de- • Defective coupler be- or short circuit) tected in the front wheel tween the front wheel sensor. sensor and the hydraulic unit assembly •...
Page 529 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Brake light switch or tail/ Brake light signal is not re- • Defective signaling sys- brake light ceived properly while the tem (tail/brake light or vehicle is traveling. (Brake brake light switch) light circuit, or front or rear •...
Page 530 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Front wheel ABS (intermit- • Pulses from the front • Incorrect installation of tent wheel speed pulses or wheel sensor are re- the front wheel sensor incorrect depressuriza- ceived intermittently •...
Page 531 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Vehicle system power Power voltage supplied to • Defective battery supply (voltage of ABS the ABS ECU in the hy- • Defective coupler be- ECU power supply is low) draulic unit assembly is tween the battery and the too low.
Page 532 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33030 COMMUNICATION ERROR WITH THE METER Probable cause of Fail-safe system Item Vehicle symptom malfunction operation U0155 [U0155] Multi-func- Communication be- Defective meter dis- Grip warmer system (YDT) tion meter: signals tween the ECU and play.
Page 533 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Lean angle sensor Lean angle sensor output Remove the lean angle voltage sensor and incline it more than 65 degrees. • Upright 0.4–1.4 • Overturned 3.7–4.4 Fuel system voltage Fuel system voltage Set the stop switch to “...
Page 534 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. EEPROM DTC display — • No history • No malfunctions detect- ed (If the DTC P062F is indicated, the ECU is de- fective.) • History exists 01–02 (CO adjustment val- •...
Page 535 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Cruise control cancel Operate the front brake circuit lever, rear brake lever, and throttle grip. • Front brake lever is squeezed • Front brake lever is re- leased •...
Page 536 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33032 DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE Diagnostic Item Actuation Procedure code No. Ignition coil Actuates the ignition coil Check that a spark is gen- five times at one-second erated five times. intervals. • Connect an ignition The “check”...
Page 537 EVENT CODE TABLE EAS20707 EVENT CODE TABLE The event code numbers listed below cannot be displayed on the meter. To display the event code numbers, use the YDT. Item Symptom Possible causes Note Intake air pres- Brief abnormality Same as for DTC No. Perform the inspection sure sensor detected in the in-...
Page 538 EVENT CODE TABLE Item Symptom Possible causes Note sensor During O feed- • Open or short circuit • If a DTC is occurring, in the wire harness respond to that first. (Stuck at the back, the adjust- between the sensor * Rarely, Code 241 oc- lower limit for ment is maintained...
Page 539 EVENT CODE TABLE Item Symptom Possible causes Note Cruise control Automatic turning The cruise control sys- The automatic turning off off of the cruise con- tem will automatically of the cruise control sys- trol system detected turn off under the fol- tem does not indicate a lowing conditions: malfunction in the sys-...
Page 540 30_EVENT EAS20552 30_EVENT EAS33033 TROUBLESHOOTING Item Latch up detected. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1. The vehicle has overturned. • Raise the overturned vehicle vertically and check again. • Push the ON/start switch, then push the OFF/LOCK switch, and then push the ON/start switch. Is the MIL on? ...
Page 541 30_EVENT Is the MIL on?  Go to step 4.  Service is completed. 4. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-93. 9-67...
Page 542 70_EVENT EAS20554 70_EVENT EAS33034 TROUBLESHOOTING Item Engine forcibly stops when the vehicle is left idling for a long period. Procedure If another error code is displayed at the same time, check the other error code first and repair it. 1. Allow to idle for a long period. •...
Page 543 P0030 EAS20397 P0030 EAS33134 TROUBLESHOOTING Item sensor heater: defective heater controller detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 544 P0030 Is the coupler condition normal?  Go to step 3. a. Connect the coupler securely or replace the wire harness. b. Push the ON/start switch, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 545 P0030 Is it in the “Recovered” condition?  Go to step 6, and complete the service.  Start the engine, and then check the condition of the DTC. Is it in the “Recovered” condition?  Go to step 6, and complete the service. ...
Page 546 P0030 Is it in the “Recovered” condition?  Go to step 6, and complete the service.  Start the engine, and then check the condition of the DTC. Is it in the “Recovered” condition?  Go to step 6, and complete the service. ...
Page 547 P00D1, P2195 EAS20660 P00D1, P2195 EAS33115 TROUBLESHOOTING Item • [P00D1] O sensor: heater performance deterioration • [P2195] O sensor: open circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. 1.
Page 548 P00D1, P2195 3. Connection of ECU coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal?  Go to step 4. a.
Page 549 P00D1, P2195 Is it in the “Recovered” condition?  Go to step 8, and complete the service.  Go to “Short circuit check”. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A”...
Page 550 P00D1, P2195 Is it in the “Recovered” condition?  Go to step 8, and complete the service.  Go to step 5. 5. Check fuel pressure. • Check the fuel pressure. Refer to “CHECKING THE FUEL PRESSURE” on page 7-12. Is check result OK? ...
Page 551 P0107, P0108 EAS20567 P0107, P0108 EAS33047 TROUBLESHOOTING Item • [P0107] Intake air pressure sensor: ground short circuit detected. • [P0108] Intake air pressure sensor: open or power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1.
Page 552 P0107, P0108 [P0108] black/blue–black/blue Between intake air pressure sensor coupler “1” [P0107, P0108] pink–pink and ECU coupler “2” [P0108] blue–blue Lg/W Lg/L Lg/L Gy/G Br/W Lg/B B/L P L Lg/W Lg/L Gy/G Br/W *. XP560D **. XP560E Is resistance 0 ? ...
Page 553 P0107, P0108 Lg/W Lg/L Lg/L Gy/G Br/W Lg/B B/L P L B/L P L Lg/W Lg/L Gy/G Br/W *. XP560D **. XP560E Is resistance  ?  Go to step 4. a. Replace the wire harness. b. Push the ON/start switch, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 554 P0107, P0108 5. Defective intake air pressure sensor. • Execute the diagnostic mode. (Code D03) • When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in- dicated. Approx. 101 kPa (757.6 mmHg, 29.8 inHg), At sea level approx.
Page 555 P0112, P0113 EAS20568 P0112, P0113 EAS33048 TROUBLESHOOTING Item • [P0112] Intake air temperature sensor: ground short circuit detected. • [P0113] Intake air temperature sensor: open or power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure Perform this procedure when the engine is cold.
Page 556 P0112, P0113 3. Wire harness continuity. • Disconnect the intake air temperature sensor coupler and ECU coupler. • Open circuit check Between intake air temperature sensor coupler [P0112, P0113] brown/white–brown/white “1” and ECU coupler “2” [P0113] black/blue–black/blue Lg/W Lg/L Lg/L Gy/G Br/W Lg/B...
Page 557 P0112, P0113 Lg/W Lg/L Lg/L Gy/G Br/W Lg/B Br/W Br/W Lg/W Lg/L Gy/G Br/W *. XP560D **. XP560E Is resistance  ?  Go to step 4. a. Replace the wire harness. b. Push the ON/start switch, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 558 P0112, P0113 Is check result OK?  Go to step 6. a. Replace the intake air temperature sensor. Refer to “GENERAL CHASSIS (3)” on page 4-17. b. Push the ON/start switch, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 559 P0117, P0118 EAS20569 P0117, P0118 EAS33049 TROUBLESHOOTING Item • [P0117] Coolant temperature sensor: ground short circuit detected. • [P0118] Coolant temperature sensor: open or power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure Perform this procedure when the engine is cold.
Page 560 P0117, P0118 3. Wire harness continuity. • Disconnect the coolant temperature sensor coupler and ECU coupler. • Open circuit check Between coolant temperature sensor coupler [P0117, P0118] green/red–green/red “1” and ECU coupler “2” [P0118] black/blue–black/blue Lg/W Lg/L Lg/L Gy/G Br/W Lg/B Lg/W Lg/L...
Page 561 P0117, P0118 Lg/W Lg/L Lg/L Gy/G Br/W Lg/B Lg/W Lg/L Gy/G Br/W *. XP560D **. XP560E Is resistance  ?  Go to step 4. a. Replace the wire harness. b. Push the ON/start switch, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 562 P0117, P0118 Is check result OK?  Go to step 6. a. Replace the coolant temperature sensor. Refer to “CYLINDER HEAD” on page 5-20. b. Push the ON/start switch, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 563 P0122, P0123, P0222, P0223, P2135 EAS20570 P0122, P0123, P0222, P0223, P2135 EAS33050 TROUBLESHOOTING Item • [P0122] Throttle position sensor: ground short circuit detected. • [P0123] Throttle position sensor: open or power short circuit detected. • [P0222] Throttle position sensor: open or ground short circuit detected. •...
Page 564 P0122, P0123, P0222, P0223, P2135 Is it in the “Recovered” condition?  Go to step 9, and complete the service.  Go to step 3. 3. Wire harness continuity. • Disconnect the throttle position sensor coupler and ECU coupler. • Open circuit check [P0122, P0222] blue–blue [P0122, P0123, P0222, P0223, P2135] Between throttle position sensor coupler “1”...
Page 565 P0122, P0123, P0222, P0223, P2135 Lines short circuit check “B” [P0122, P0123, P0222, P0223, P2135] white–any other coupler terminal [P0122, P0222] blue–any other coupler terminal Throttle position sensor coupler “1” [P0123, P0223] black/blue–any other coupler terminal [P0122, P0123, P0222, P0223, P2135] black–any other coupler terminal [P0122, P0222] blue–any other coupler terminal [P0122, P0123, P0222, P0223, P2135]...
Page 566 P0122, P0123, P0222, P0223, P2135 4. Installed condition of throttle position sensor. • Check for looseness or pinching. Refer to “CHECKING THE THROTTLE POSITION SENSOR” on page 8-107. Is check result OK?  Go to step 5. a. Reinstall or adjust the sensor. b.
Page 567 P0122, P0123, P0222, P0223, P2135 Is it in the “Recovered” condition?  Go to step 9, and complete the service.  Go to step 7. 7. Defective throttle position sensor. • Check throttle position sensor signal 2. • Execute the diagnostic mode. (Code D13) When the throttle valves are fully closed 9–23 When throttle valves are fully open...
Page 568 P0132 EAS20571 P0132 EAS33051 TROUBLESHOOTING Item sensor: short circuit detected (power short circuit). Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Installed condition of O sensor. • Check for looseness or pinching. Refer to “ENGINE REMOVAL” on page 5-7. Is check result OK? ...
Page 569 P0132 3. Connection of ECU coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal?  Go to step 4. a.
Page 570 P0132 Is it in the “Recovered” condition?  Go to step 7, and complete the service.  Go to “Short circuit check”. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A”...
Page 571 P0132 Is resistance  ?  Go to step 5. a. Replace the wire harness. b. Push the ON/start switch, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? ...
Page 572 P0201 EAS20574 P0201 EAS33054 TROUBLESHOOTING Item Injector #1: malfunction in injector #1. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1. Connection of injector #1 coupler. •...
Page 573 P0201 3. Connection of ECU coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal?  Go to step 4. a.
Page 574 P0201 • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A” red/black–ground Between injector #1 coupler “1” and ground red/blue–ground Lines short circuit check “B” red/black–any other coupler terminal Injector #1 coupler “1”...
Page 575 P0202 EAS20575 P0202 EAS33055 TROUBLESHOOTING Item Injector #2: malfunction in injector #2. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1. Connection of injector #2 coupler. •...
Page 576 P0202 3. Connection of ECU coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal?  Go to step 4. a.
Page 577 P0202 • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A” green/black–ground Between injector #2 coupler “1” and ground red/blue–ground Lines short circuit check “B” green/black–any other coupler terminal Injector #2 coupler “1”...
Page 578 P0335 EAS20578 P0335 EAS33058 TROUBLESHOOTING Item Crankshaft position sensor: no normal signals are received from the crankshaft position sensor. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1. Connection of crankshaft position sensor coupler. • Check the locking condition of the coupler. •...
Page 579 P0335 Lg/W Lg/L Lg/L Gy/G Br/W Lg/B B/Y B/L Lg/W Lg/L Gy/G Br/W *. XP560D **. XP560E Is resistance 0 ?  Go to “Short circuit check”. a. Replace the wire harness. b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 580 P0335 Lg/W Lg/L Lg/L Gy/G Br/W Lg/B B/Y B/L B/Y B/L Lg/W Lg/L Gy/G Br/W *. XP560D **. XP560E Is resistance  ?  Go to step 4. a. Replace the wire harness. b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 581 P0335 5. Defective crankshaft position sensor. • Check the crankshaft position sensor. Refer to “CHECKING THE CRANKSHAFT POSITION SENSOR” on page 8-104. Is check result OK?  Go to step 6. a. Replace the crankshaft position sensor. b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 582 P0351 EAS20580 P0351 EAS33060 TROUBLESHOOTING Item Ignition coil: open or short circuit detected in the primary lead of the ignition coil. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1. Connection of ignition coil coupler. •...
Page 583 P0351 Is resistance 0 ?  Go to “Short circuit check”. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 584 P0351 Is resistance  ?  Go to step 4. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 585 P0351 6. Malfunction in ECU. • Execute the diagnostic mode. (Code D30) • Confirm that spark plug does not sparking. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-93. 7. Delete the DTC and check that the MIL goes off. •...
Page 586 P0480 EAS20585 P0480 EAS33065 TROUBLESHOOTING Item Radiator fan motor relay: open or short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of radiator fan motor relay coupler. • Check the locking condition of the coupler. •...
Page 587 P0480 3. Wire harness continuity. • Disconnect the radiator fan motor relay coupler, ECU coupler and ignition fuse. • Open circuit check Between radiator fan motor relay coupler “1” red/white–red/white and ignition fuse holder “3” Between radiator fan motor relay coupler “1” yellow/red–yellow/red and ECU coupler “2”...
Page 588 P0480 Br/B Br/B Is resistance  ?  Go to step 4. a. Replace the wire harness. b. Push the ON/start switch, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? ...
Page 589 P0500 EAS20674 P0500 EAS33303 TROUBLESHOOTING Item Rear wheel sensor: no normal signals are received from the rear wheel sensor. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of rear wheel sensor coupler. • Check the locking condition of the coupler. •...
Page 590 P0500 Is the coupler condition normal?  Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code D07) c. Rotate the rear wheel by hand and check that the indicated value increases. Is that value increased? ...
Page 591 P0500 • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A” black–ground Between ABS ECU coupler “2” and ground white–ground white/green–ground Lines short circuit check “B” black–any other coupler terminal Rear wheel sensor coupler “1”...
Page 592 P0500 Is that value increased?  Go to step 7.  Go to step 6. 6. Malfunction in ABS ECU. • Replace the ABS ECU and go to step 7 7. Delete the DTC and check that the MIL goes off. •...
Page 593 P0507 EAS20589 P0507 EAS33069 TROUBLESHOOTING Item Engine idling speed is too high. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 594 P0507 3. Malfunction in ECU. • Replace the ECU, and complete the service. 4. Delete the DTC and check that the MIL goes off. • Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC. 9-120...
Page 595 P0560, P0563 EAS20434 P0560, P0563 EAS33138 TROUBLESHOOTING Item • [P0560] Charging voltage is abnormal. • [P0563] Vehicle system power voltage out of range Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 596 P0564 EAS20594 P0564 EAS33074 TROUBLESHOOTING Item • Cruise control setting switch “RES+”: open or short circuit is detected. • Cruise control setting switch “SET–”: open or short circuit is detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1.
Page 597 P0564 Perform the procedure from step 6 to step 10. 3. Check the fuse. • Check the ignition fuse and cruise control fuse. Is check result OK? Go to step 4. a. Replace the fuse. b. Push the ON/start switch. c.
Page 598 P0564 Is resistance 0 ? Go to “Short circuit check”. a. Replace the wire harness. b. Push the ON/start switch. c. Push and release the “RES+” side of the cruise control setting switch, and then check the condi- tion of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 599 P0564 Is resistance  ? Go to step 5. a. Replace the wire harness. b. Push the ON/start switch. c. Push and release the “RES+” side of the cruise control setting switch, and then check the condi- tion of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 600 P0564 7. Wire harness continuity. • Open circuit check • Disconnect the ignition system relay coupler, ignition fuse, handlebar switch coupler (left) and ECU coupler. Between ignition system relay coupler “1” and brown/blue–brown/blue ignition fuse holder “2” Between ignition fuse holder “2” and handlebar yellow/black–yellow/black switch coupler (left) “3”...
Page 601 P0564 Lines short circuit check “B” Ignition system relay coupler “1” brown/blue–any other coupler terminal green/blue–any other coupler terminal Handlebar switch coupler (left) “3” yellow/black–any other coupler terminal ECU coupler “4” green/blue–any other coupler terminal Br/L Lg/W Lg/L Br/L Lg/L Gy/G Br/W Lg/B...
Page 602 P056C EAS20595 P056C EAS33075 TROUBLESHOOTING Item • Front brake light switch: open or short circuit is detected. • Rear brake light switch: open or short circuit is detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1.
Page 603 P056C Is it in the “Recovered” condition? Go to step 11, and complete the service. Go to step 3. 3. Check the fuse. (signaling system fuse and brake light fuse) Is check result OK? Go to step 4. a. Replace the fuse. b.
Page 604 P056C Is resistance 0 ? Go to “Short circuit check”. a. Replace the wire harness. b. Push the ON/start switch. c. Operate the front brake lever, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 605 P056C G/W Y/W Br/L G/Y Y/B Br/L G/W Y/W G/Y Y/B Lg/W Lg/L Lg/B G/Y B Lg/L Gy/G Br/W Lg/B G/Y B Lg/B Is resistance  ? Go to step 5. a. Replace the wire harness. b. Push the ON/start switch. c.
Page 606 P056C Is the coupler condition normal? Go to step 7. a. Connect the coupler securely or replace the wire harness. b. Push the ON/start switch. c. Operate the rear brake lever, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 607 P056C Lg/W Lg/L G/Y Y/B Br/L Lg/L Gy/G Br/W Lg/B Y/W Lg/B G/Y B Lg/B Is resistance 0 ? Go to “Short circuit check”. a. Replace the wire harness. b. Push the ON/start switch. c. Operate the rear brake lever, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 608 P056C G/Y Y/B Br/L Br/L G/Y Y/B Lg/B Y/W Lg/B Y/W Lg/W Lg/L Lg/L Gy/G Br/W Lg/B G/Y B Lg/B G/Y B Lg/B Is resistance  ? Go to step 9. a. Replace the wire harness. b. Push the ON/start switch. c.
Page 609 P056C 10.Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-93. 11.Delete the DTC and check that the MIL goes off. • Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC. 9-135...
Page 610 P0601 EAS20676 P0601 EAS33305 TROUBLESHOOTING Item Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC might not appear on the tool display.) Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1.
Page 611 P0606 EAS20677 P0606 EAS33306 TROUBLESHOOTING Item Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC might not appear on the tool display.) Fail-safe system • Able/Unable to start engine • Able/Unable to drive vehicle Procedure 1.
Page 612 P062F EAS20598 P062F EAS33078 TROUBLESHOOTING Item EEPROM DTC: an error is detected while reading or writing on EEPROM. Fail-safe system • Able/Unable to start engine • Able/Unable to drive vehicle Procedure 1. Locate the malfunction. • Execute the diagnostic mode (Code D60) Go to step 5.
Page 613 P062F 4. Except “00-04” is indicated in diagnostic mode (Code D60). EEPROM data error for corresponding learning/memory values. • Push the OFF/LOCK switch. • Push the ON/start switch, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 614 P0638 EAS20599 P0638 EAS33079 TROUBLESHOOTING Item YCC-T drive system: malfunction detected. Fail-safe system • Able/Unable to start engine • Able/Unable to drive vehicle Procedure 1. Connection of throttle servo motor coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins).
Page 615 P0638 3. Check the electronic throttle valve fuse. Is check result OK?  Go to step 4. a. Replace the electronic throttle valve fuse. b. Push the ON/start switch, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 616 P0638 Ground short circuit check “A” yellow/red–ground Between ECU coupler “2” and ground yellow/white–ground red/blue–ground Lines short circuit check “B” yellow/red–any other coupler terminal Throttle servo motor coupler “1” yellow/white–any other coupler terminal yellow/red–any other coupler terminal ECU coupler “2” yellow/white–any other coupler terminal red/blue–any other coupler terminal Is resistance ...
Page 617 P0638 Is it in the “Recovered” condition?  Go to step 8, and complete the service.  Go to step 6. 6. Defective throttle bodies. • Check the throttle bodies. Refer to “CHECKING THE THROTTLE SERVO MOTOR” on page 8-108. Is check result OK? ...
Page 618 P0657 EAS20601 P0657 EAS33081 TROUBLESHOOTING Item Fuel system voltage: incorrect voltage supplied to the injector and fuel pump. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 619 P0657 3. Wire harness continuity. • Disconnect the fuel injection system fuse, fuel injection system relay coupler, ignition fuse, handle- bar switch coupler (right) and ECU coupler. • Open circuit check Between fuel injection system fuse holder “1” red–red and fuel injection system relay coupler “2” Between ignition fuse holder “3”...
Page 620 P0657 Lines short circuit check “B” red–any other coupler terminal red/blue–any other coupler terminal Fuel injection system relay coupler “2” red/black–any other coupler terminal blue/yellow–any other coupler terminal red/white–any other coupler terminal Handlebar switch coupler (right) “4” red/black–any other coupler terminal red/blue–any other coupler terminal ECU coupler “5”...
Page 621 P0657 Is it in the “Recovered” condition?  Go to step 7, and complete the service.  Go to step 5. 5. Defective fuel injection system relay. • Execute the diagnostic mode. (Code D09) Is the fuel system voltage less than 3V? a.
Page 622 P1601 EAS20614 P1601 EAS33094 TROUBLESHOOTING Item Sidestand switch: open or short circuit of the light green lead of the ECU is detected. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1. Connection of sidestand switch coupler. •...
Page 623 P1601 Is the coupler condition normal?  Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Push the ON/start switch, and then extend and retract the sidestand. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 624 P1601 • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A” Between sidestand relay coupler “1” and ground light green–ground Between sidestand switch coupler “3” and light green–ground ground Lines short circuit check “B”...
Page 625 P1601 5. Defective sidestand switch. • Execute the diagnostic mode. (Code D20) Sidestand retracted Sidestand extended Is check result OK?  Go to step 6. a. Replace the sidestand switch. b. Push the ON/start switch, and then extend and retract the sidestand. c.
Page 626 P1602 EAS20615 P1602 EAS33095 TROUBLESHOOTING Item Malfunction in ECU internal circuit (malfunction of ECU power cut-off function). Fail-safe system • Able/Unable to start engine • Able/Unable to drive vehicle Procedure 1. Installed condition of battery leads. • Check the installed condition of the battery and battery leads (loose bolts). Is check result OK? ...
Page 627 P1602 3. Check the main fuse. Is check result OK?  Go to step 4. a. Replace the fuse. b. Push the ON/start switch, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? ...
Page 628 P1602 Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A” Between starter relay coupler “3” and ground red–ground Lines short circuit check “B” Starter relay coupler “3” red–any other coupler terminal ECU coupler “4”...
Page 629 P1604, P1605 EAS20617 P1604, P1605 EAS33097 TROUBLESHOOTING Item • [P1604] Lean angle sensor: ground short circuit detected. • [P1605] Lean angle sensor: open or power short circuit. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1.
Page 630 P1604, P1605 [P1604] blue–blue Between lean angle sensor coupler “1” and [P1604, P1605] yellow/green–yellow/green ECU coupler “2” [P1605] black/blue–black/blue Lg/W Lg/L Lg/L Gy/G Br/W Lg/B Lg/W Lg/L Gy/G Br/W *. XP560D **. XP560E Is resistance 0 ? Go to “Short circuit check”. a.
Page 631 P1604, P1605 Lg/W Lg/L Lg/L Gy/G Br/W Lg/B Lg/W Lg/L Gy/G Br/W *. XP560D **. XP560E Is resistance  ? Go to step 4. a. Replace the wire harness. b. Push the ON/start switch, then to “OFF”, and then back to “ON”. c.
Page 632 P2122, P2123, P2127, P2128, P2138 EAS20632 P2122, P2123, P2127, P2128, P2138 EAS33112 TROUBLESHOOTING Item • [P2122] Accelerator position sensor: open or ground short circuit detected. • [P2123] Accelerator position sensor: power short circuit detected. • [P2127] Accelerator position sensor: ground short circuit detected. •...
Page 633 P2122, P2123, P2127, P2128, P2138 Is it in the “Recovered” condition?  Go to step 6, and complete the service.  Go to step 3. 3. Wire harness continuity. • Disconnect the accelerator position sensor coupler and ECU coupler. • Open circuit check [P2122, P2123, P2127, P2128, P2138] white–white Between accelerator position sensor coupler “1”...
Page 634 P2122, P2123, P2127, P2128, P2138 Lines short circuit check “B” [P2122, P2123, P2127, P2128, P2138] white–any other coupler terminal [P2123, P2128] black/blue–any other coupler Accelerator position sensor coupler “1” terminal [P2122, P2127] blue–any other coupler terminal [P2122, P2123, P2127, P2128, P2138] red–any other coupler terminal [P2122, P2123, P2127, P2128, P2138] white–any other coupler terminal...
Page 635 P2122, P2123, P2127, P2128, P2138 Is check result OK?  Go to step 5.  Replace the accelerator position sensor Refer to “HANDLEBAR” on page 4-74. Is it in the “Recovered” condition?  Go to step 6, and complete the service. ...
Page 636 P2158 EAS20633 P2158 EAS33113 TROUBLESHOOTING Item Front wheel sensor: no normal signals are received from the front wheel sensor. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of front wheel sensor coupler. • Check the locking condition of the coupler. •...
Page 637 P2158 3. Connection of ECU coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal?  Go to step 4. a.
Page 638 P2158 Is that value increased?  Go to step 8, and complete the service.  Go to “Short circuit check”. • Short circuit check Disconnect the ECU and ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3 and “PARTS CONNECTED TO THE ABS ECU”...
Page 639 P2158 Is resistance  ?  Go to step 5. a. Replace the wire harness. b. Execute the diagnostic mode. (Code D16) c. Rotate the front wheel by hand and check that the indicated value increases. Is that value increased? ...
Page 640 U0155 or Err EAS20649 U0155 or Err EAS33129 TROUBLESHOOTING Item Multi-function meter: signals cannot be transmitted between the ECU and the multi-function meter. Fail-safe system • Able to start engine • Able to drive vehicle Procedure “Err” is displayed on the clock display of the multi-function meter, but the MIL does not come on. 1.
Page 641 U0155 or Err 3. Wire harness continuity. • Disconnect the meter assembly coupler and ECU coupler. • Open circuit check Between meter assembly coupler “1” and ECU light green/white–light green/white coupler “2” light green/blue–light green/blue Lg/W Lg/L Lg/L Gy/G Br/W Lg/B P/W P/B O/L R/L B/W Br/Y L/R Br/Y ChDgR/GR/W...
Page 642 U0155 or Err P/W P/B O/L R/L B/W Br/Y L/R Br/Y ChDgR/GR/W Gy V Gy/W V/WG/R G/L G W/GW/RW/L Y B/WLg/WLg/LB/WR/GR/G P/W P/B O/L R/L B/W Br/Y L/R Br/Y ChDgR/GR/W Lg/W Lg/L Gy V Gy/W V/WG/R G/L G W/GW/RW/L Y B/WLg/WLg/LB/WR/GR/G Lg/L Gy/G Br/W...
Page 643 11, 25_ABS EAS20685 11, 25_ABS EAS33314 TROUBLESHOOTING Item Front wheel sensor (intermittent pulses or no pulses) Procedure With the front wheel stopped, the rear wheel was rotated for longer than about 20 seconds (DTC No. 11) or for longer than about 2 seconds (DTC No. 25). 1.
Page 644 12_ABS EAS20686 12_ABS EAS33315 TROUBLESHOOTING Item Rear wheel sensor (intermittent pulses or no pulses) Procedure 1. Foreign material adhered around the rear wheel sensor • Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles. Is check result OK? ...
Page 645 13, 26_ABS EAS20687 13, 26_ABS EAS33316 TROUBLESHOOTING Item Front wheel sensor (abnormal pulse period) Procedure • If the front brake ABS operates continuously for 20 seconds or more, DTC No. 26 will be recorded. If the front brake ABS operates continuously for 36 seconds or more, DTC No. 13 will be recorded. •...
Page 646 14, 27_ABS EAS20688 14, 27_ABS EAS33317 TROUBLESHOOTING Item Rear wheel sensor (abnormal pulse period) Procedure • If the rear brake ABS operates continuously for 20 seconds or more, DTC No. 27 will be recorded. If the rear brake ABS operates continuously for 36 seconds or more, DTC No. 14 will be recorded. •...
Page 647 15_ABS EAS20662 15_ABS EAS33040 TROUBLESHOOTING Item Front wheel sensor (open or short circuit) Procedure 1. Defective coupler between the front wheel sensor and the hydraulic unit assembly • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. Push the OFF/LOCK switch before disconnecting or connecting a coupler.
Page 648 15_ABS Lines short circuit check “B” white–any other coupler terminal ABS ECU coupler “1” black–any other coupler terminal white–any other coupler terminal Front wheel sensor “2” black–any other coupler terminal Br/W Lg/L Lg/W Lg/L Lg/W Br/W Is resistance  ? ...
Page 649 16_ABS EAS20663 16_ABS EAS33285 TROUBLESHOOTING Item Rear wheel sensor (open or short circuit) Procedure 1. Defective coupler between the rear wheel sensor and the hydraulic unit assembly • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. Push the OFF/LOCK switch before disconnecting or connecting a coupler.
Page 650 16_ABS Lines short circuit check “B” white–any other coupler terminal ABS ECU coupler “1” black–any other coupler terminal white–any other coupler terminal Rear wheel sensor “2” black–any other coupler terminal Br/W Lg/L Lg/W Br/W Lg/L Lg/W Is resistance  ? ...
Page 651 17, 45_ABS EAS20708 17, 45_ABS EAS33372 TROUBLESHOOTING Item Front wheel sensor (missing pulses) Procedure If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, DTC No. 17 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, DTC No. 45 will be recorded first and DTC No.
Page 652 18, 46_ABS EAS20709 18, 46_ABS EAS33373 TROUBLESHOOTING Item Rear wheel sensor (missing pulses) Procedure If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, DTC No. 18 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, DTC No. 46 will be recorded first and DTC No.
Page 653 21_ABS EAS20690 21_ABS EAS33320 TROUBLESHOOTING Item Hydraulic unit assembly (defective solenoid drive circuit) Procedure 1. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (Anti-lock Brake System)” on page 4-67. 9-179...
Page 654 24_ABS EAS20710 24_ABS EAS33374 TROUBLESHOOTING Item Brake light switch or tail/brake light Procedure 1. Defective signaling system (tail/brake light or brake light switch) • Check the brake light switches. Refer to “CHECKING THE SWITCHES” on page 8-91. Is check result OK? ...
Page 655 24_ABS Is resistance 0 ?  Go to “Short circuit check”.  Replace the wire harness. • Short circuit check Disconnect the ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4. Ground short circuit check “A” Between ABS ECU coupler “3”...
Page 656 24_ABS G/W Y/W G/Y Y/B G/Y Y/B Lg/B Y/W Lg/B G/Y B Br/W Lg/L Lg/W Is resistance 0 ?  Go to “Short circuit check”.  Replace the wire harness. • Short circuit check Disconnect the ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ABS ECU”...
Page 657 24_ABS Is resistance  ?  Go to step 5.  Replace the wire harness. 5. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “CHECKING THE FUEL PRESSURE” on page 7-12. 9-183...
Page 658 31_ABS EAS20691 31_ABS EAS33321 TROUBLESHOOTING Hydraulic unit assembly (defective ABS solenoid power supply) Procedure 1. Blown ABS solenoid fuse • Check the ABS solenoid fuse. Refer to “CHECKING THE FUSES” on page 8-93. Is check result OK?  Go to step 2. ...
Page 659 31_ABS Disconnect the ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4. Ground short circuit check “A” Between ABS ECU coupler “2” and ground red/white–ground Lines short circuit check “B” ABS ECU coupler “2” red/white–any other coupler terminal Lg/L Lg/W...
Page 660 32_ABS EAS20712 32_ABS EAS33376 TROUBLESHOOTING Item Hydraulic unit assembly (short circuit in ABS solenoid power supply circuit) Procedure 1. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (Anti-lock Brake System)” on page 4-67. 9-186...
Page 661 33_ABS EAS20692 33_ABS EAS33322 TROUBLESHOOTING Item Hydraulic unit assembly (abnormal ABS motor power supply) Procedure 1. Blown ABS motor fuse • Check the ABS motor fuse. Refer to “CHECKING THE FUSES” on page 8-93. Is check result OK?  Go to step 2. ...
Page 662 33_ABS • Short circuit check Disconnect the ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4. Ground short circuit check “A” Between ABS ECU coupler “2” and ground red/blue–ground Lines short circuit check “B” red/blue–any other coupler terminal ABS ECU coupler “2”...
Page 663 34_ABS EAS20693 34_ABS EAS33323 TROUBLESHOOTING Item Hydraulic unit assembly (short circuit in ABS motor power supply circuit) Procedure 1. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (Anti-lock Brake System)” on page 4-67. 9-189...
Page 664 41_ABS EAS20694 41_ABS EAS33331 TROUBLESHOOTING Item Front wheel ABS (intermittent wheel speed pulses or incorrect depressurization) Procedure 1. Incorrect installation of the front wheel sensor • Check the components for looseness, distortion, and bends. Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4- Is check result OK? ...
Page 665 42, 47_ABS EAS20695 42, 47_ABS EAS33324 TROUBLESHOOTING Item Rear wheel ABS (intermittent wheel speed pulses or incorrect depressurization) Procedure 1. Incorrect installation of the rear wheel sensor (DTC No. 42) • Check the components for looseness, distortion, and bends. Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR” on page 4- Is check result OK? ...
Page 666 43_ABS EAS20696 43_ABS EAS33330 TROUBLESHOOTING Item Front wheel sensor (missing pulses) Procedure 1. Foreign material adhered around the front wheel sensor • Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles. Is check result OK? ...
Page 667 44_ABS EAS20697 44_ABS EAS33325 TROUBLESHOOTING Item Rear wheel sensor (missing pulses) Procedure 1. Foreign material adhered around the rear wheel sensor • Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles. Is check result OK? ...
Page 668 51, 52_ABS EAS20698 51, 52_ABS EAS33326 TROUBLESHOOTING Item • Vehicle system power supply (voltage of ABS ECU power supply is high) (DTC No. 51) • Vehicle system power supply (voltage of wheel sensor power supply is high) (DTC No. 52) Procedure 1.
Page 669 53_ABS EAS20699 53_ABS EAS33327 TROUBLESHOOTING Item Vehicle system power supply (voltage of ABS ECU power supply is low) Procedure 1. Defective battery • Recharge or replace the battery, and check again. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-94. 2.
Page 670 53_ABS Lines short circuit check “B” ABS ECU coupler “2” brown/white–any other coupler terminal Lg/L Lg/W Br/W Br/W Lg/L Lg/W Is resistance  ?  Go to step 4.  Replace the wire harness. 4. Defective charging system • Check the charging system. Refer to “CHARGING SYSTEM”...
Page 671 54_ABS EAS20711 54_ABS EAS33375 TROUBLESHOOTING Item Hydraulic unit assembly (defective ABS solenoid and ABS motor power supply circuits) Procedure 1. Defective battery • Recharge or replace the battery, and check again. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-94. 2.
Page 672 54_ABS Ground short circuit check “A” brown/white–ground Between ABS ECU coupler “3” and ground red/blue–ground Lines short circuit check “B” brown/white–any other coupler terminal ABS ECU coupler “3” red/blue–any other coupler terminal Lg/L Lg/W Lg/L Lg/W Br/W Br/W Is resistance  ? ...
Page 673 55_ABS EAS20700 55_ABS EAS33328 TROUBLESHOOTING Item Hydraulic unit assembly (defective ABS ECU) Procedure 1. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (Anti-lock Brake System)” on page 4-67. 9-199...
Page 674 56_ABS EAS20701 56_ABS EAS33329 TROUBLESHOOTING Item Hydraulic unit assembly (abnormal internal power supply) Procedure 1. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (Anti-lock Brake System)” on page 4-67. 9-200...
Page 675 63_ABS EAS20703 63_ABS EAS33334 TROUBLESHOOTING Item Front wheel sensor power supply (voltage of power supply is low) Procedure 1. Wire harness continuity. Disconnect the ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4. Ground short circuit check “A”...
Page 676 63_ABS W Gy W Gy Is resistance  ?  Go to step 3.  Replace the wire harness. 3. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (Anti-lock Brake System)” on page 9-26. 9-202...
Page 677 64_ABS EAS20704 64_ABS EAS33335 TROUBLESHOOTING Item Rear wheel sensor power supply (voltage of power supply is low) Procedure 1. Wire harness continuity. Disconnect the ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4. Ground short circuit check “A”...
Page 678 64_ABS W Gy W Gy Is resistance  ?  Go to step 3.  Replace the wire harness. 3. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (Anti-lock Brake System)” on page 9-26. 9-204...
Page 679 54. ABS warning light A. Wire harness EAS20091 WIRING DIAGRAM 55. High beam indicator light B. Negative battery sub-wire har- 56. Multi-function display ness XP560E 2020 57. ECU (Engine Control Unit) C. Headlight sub-wire harness 1. Battery charger terminal 58. Ignition coil 2.
Page 680 XP560D 2020 56. Smart key system indicator 110.Headlight (high) light 111.Headlight (low) 1. Battery charger terminal 57. Meter light 112.Headlight control unit 2. Remote control unit 58. Tachometer 113.Cruise control fuse 3. OFF/LOCK switch 59. Fuel level warning light 114.Auxiliary DC jack 4.
Page 681 EAS30613 COLOR CODE Black Brown Chocolate Dark green Green Gray Blue Light green Orange Pink Sky blue Violet White Yellow Black/Green Black/Blue Black/White Black/Yellow Br/B Brown/Black Br/L Brown/Blue Br/R Brown/Red Br/W Brown/White Br/Y Brown/Yellow Green/Black Green/Blue Green/Red Green/White Green/Yellow Gy/G Gray/Green Gy/W Gray/White...
Page 685 XP560E 2020 WIRING DIAGRAM B/L B/L Br/R R Br Lg L/GLg/W R/B G/L L/R Br/B W/YL/W G/YLg/L Y/L B L R/G L/Y Br R R R R R Br/R Br/R Br/R (Gy) B/Y B/L (Gy) R/G Br/R O/L Br/R W W W Br/W Br/W B L/R...
Page 686 XP560E 2020 WIRING DIAGRAM (Gy) (Gy) FREE PUSH (Gy) (Gy) PUSH FREE FREE PUSH PASS DOWN (Gy)
Page 687 XP560D 2020 WIRING DIAGRAM B/L B/L G/W Y/W G/Y Y/B R Br Lg L/GLg/W R/B G/L L/R Br/B W/YL/W Y/W G/Y R Br G G/YLg/L Y/L B L R/G L/Y Br R R R R R (Gy) Br Y G G/Y Y/B B/Y B/L Lg/B Y/W...
Page 688 XP560D 2020 WIRING DIAGRAM (Gy) (Gy) FREE PUSH (Gy) (Gy) PUSH FREE PUSH FREE FREE PUSH FREE PASS DOWN (Gy)

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Tmax tech max 2020 Xp560el Xp560d

Yamaha TMAX 2020 Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

General Chassis (1)

General Chassis (2)

General Chassis (3)

Front Wheel

Rear Wheel

Front Brake

Rear Brake

ABS (Anti-Lock Brake System)

Handlebar

Front Fork

Steering Head

Belt Drive

Rear Shock Absorber Assembly

Swingarm

Engine

Lubrication System Chart and Diagrams

Engine Inspection

Engine Removal

Camshafts

Cylinder Head

Valves and Valve Springs

Cylinder and Pistons

Electric Starter

V-Belt Automatic Transmission

Generator and Starter Clutch

Clutch

Oil Pump

Crankcase

Crankshaft

Transmission

Cooling System

Cooling System Diagrams

Radiator

Oil Cooler

Thermostat

Water Pump

Fuel System

Fuel Tank

Throttle Body

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Yamaha TMAX 2020